Method for manufacturing semiconductor device

ABSTRACT

A highly reliable semiconductor device which includes a thin film transistor having stable electric characteristics, and a manufacturing method thereof. In the manufacturing method of the semiconductor device which includes a thin film transistor where a semiconductor layer including a channel formation region is an oxide semiconductor layer, heat treatment which reduces impurities such as moisture to improve the purity of the oxide semiconductor layer and oxidize the oxide semiconductor layer (heat treatment for dehydration or dehydrogenation) is performed. Not only impurities such as moisture in the oxide semiconductor layer but also those existing in a gate insulating layer are reduced, and impurities such as moisture existing in interfaces between the oxide semiconductor layer and films provided over and under and in contact with the oxide semiconductor layer are reduced.

TECHNICAL FIELD

The present invention relates to a semiconductor device including anoxide semiconductor and a manufacturing method thereof.

In this specification, a semiconductor device generally refers to anydevice which can function by utilizing semiconductor characteristics: anelectro-optic device, a semiconductor circuit, and an electronic deviceare all included in the category of the semiconductor device.

BACKGROUND ART

In recent years, a technique by which a thin film transistor (TFT) ismanufactured using a semiconductor thin layer (having a thickness ofabout several nanometers to several hundred nanometers) formed over asubstrate having an insulating surface has attracted attention. Thinfilm transistors have been applied to a wide range of electronic devicessuch as ICs or electro-optic devices and urgently developed particularlyas switching elements in image display devices. Various metal oxides areused for a variety of applications. Indium oxide is a well-knownmaterial and has been used as a transparent electrode material which isnecessary for liquid crystal displays and the like.

Some metal oxides exhibit semiconductor characteristics. As examples ofmetal oxides exhibiting semiconductor characteristics, tungsten oxide,tin oxide, indium oxide, zinc oxide, and the like can be given, and thinfilm transistors in each of which a channel formation region is formedusing such a metal oxide exhibiting semiconductor characteristics arealready known (see Patent Documents 1 to 5 and Non-Patent Document 1).

Further, not only single-component oxides but also multi-componentoxides are known as metal oxides. For example, InGaO₃(ZnO)_(m) (m:natural number) having a homologous series is known as a multi-componentoxide semiconductor including In, Ga, and Zn (see Non-Patent Documents 2to 4).

Further, it has been confirmed that an oxide semiconductor includingsuch an In—Ga—Zn—O-based oxide is applicable to a channel layer of athin film transistor (see Patent Document 6 and Non-Patent Documents 5and 6).

REFERENCE Patent Document

-   Patent Document 1: Japanese Published Patent Application No.    S60-198861-   Patent Document 2: Japanese Published Patent Application No.    H08-264794-   Patent Document 3: Japanese Translation of PCT International    Application No. H11-505377-   Patent Document 4: Japanese Published Patent Application No.    2000-150900-   Patent Document 5: Japanese Published Patent Application No.    2007-123861-   Patent Document 6: Japanese Published Patent Application No.    2004-103957

Non-Patent Document

-   Non-Patent Document 1: M. W. Prins, K. O. Grosse-Holz, G.    Muller, J. F. M. Cillessen, J. B. Giesbers, R. P. Weening, and R. M.    Wolf, “A ferroelectric transparent thin-film transistor,” Appl.    Phys. Lett., 17 Jun. 1996, Vol. 68, pp. 3650-3652-   Non-Patent Document 2: M. Nakamura, N. Kimizuka, and T. Mohri, “The    Phase Relations in the In₂O₃—Ga₂ZnO₄—ZnO System at 1350° C.”, J.    Solid State Chem., 1991, Vol. 93, pp. 298-315-   Non-Patent Document 3: N. Kimizuka, M. Isobe, and M. Nakamura,    “Syntheses and Single-Crystal Data of Homologous Compounds,    In₂O₃(ZnO), (m=3, 4, and 5), InGaO₃(ZnO)₃, and Ga₂O₃(ZnO)_(m) (m=7,    8, 9, and 16) in the In₂O₃—ZnGa₂O₄—ZnO System”, J. Solid State    Chem., 1995, Vol. 116, pp. 170-178-   Non-Patent Document 4: M. Nakamura, N. Kimizuka, T. Mohri, and M.    Isobe, “Syntheses and crystal structures of new homologous    compounds, indium iron zinc oxides (InFeO₃(ZnO)_(m)) (m: natural    number) and related compounds”, KOTAI BUTSURI (SOLID STATE PHYSICS),    1993, Vol. 28, No. 5, pp. 317-327-   Non-Patent Document 5: K. Nomura, H. Ohta, K. Ueda, T. Kamiya, M.    Hirano, and H. Hosono, “Thin-film transistor fabricated in    single-crystalline transparent oxide semiconductor”, SCIENCE, 2003,    Vol. 300, pp. 1269-1272-   Non-Patent Document 6: K. Nomura, H. Ohta, A. Takagi, T. Kamiya, M.    Hirano, and H. Hosono, “Room-temperature fabrication of transparent    flexible thin-film transistors using amorphous oxide    semiconductors”, NATURE, 2004, Vol. 432, pp. 488-492

DISCLOSURE OF INVENTION

It is an object of the present invention to manufacture and provide ahighly reliable semiconductor device which includes a thin filmtransistor having stable electric characteristics.

In a method for manufacturing a semiconductor device which includes athin film transistor where a semiconductor layer including a channelformation region is an oxide semiconductor layer, heat treatment whichreduces impurities such as moisture to improve the purity of the oxidesemiconductor layer (heat treatment for dehydration or dehydrogenation)is performed in an oxygen atmosphere. In addition, not only impuritiessuch as moisture in the oxide semiconductor layer but also thoseexisting in a gate insulating layer are reduced, and impurities such asmoisture existing in interfaces between the oxide semiconductor layerand films provided over and under and in contact with the oxidesemiconductor layer are reduced. Further, the heat treatment can oxidizethe oxide semiconductor layer.

In order to reduce impurities such as moisture, the oxide semiconductorlayer is subjected to heat treatment in an oxygen atmosphere afterformed, so that moisture existing in the oxide semiconductor layer isreduced and the oxide semiconductor layer is oxidized. The heattreatment is performed at a temperature higher than or equal to 200° C.and lower than the strain point, preferably higher than or equal to 400°C. and lower than or equal to 700° C. After the heat treatment, it ispreferable that the oxide semiconductor layer be slowly cooled in the/anoxygen atmosphere or an inert gas atmosphere of nitrogen or a rare gas(such as helium or argon).

In this specification, the oxygen atmosphere refers to an atmosphere ofa gas containing an oxygen atom, typically refers to an atmosphere ofoxygen, ozone, or a nitrogen oxide (such as nitrogen monoxide, nitrogendioxide, dinitrogen monoxide, dinitrogen trioxide, dinitrogentetraoxide, or dinitrogen pentoxide). The oxygen atmosphere may containan inert gas of nitrogen or a rare gas (such as helium or argon); inthat case, the amount of the inert gas is less than that of the gascontaining an oxygen atom.

In this specification, heat treatment in an oxygen atmosphere, by whichan oxide semiconductor layer is oxidized while performing dehydration ordehydrogenation thereon is referred to as heat treatment for dehydrationor dehydrogenation. In this specification, dehydrogenation does notrefer to only elimination in the form of H₂ by the heat treatment, anddehydration or dehydrogenation also refer to elimination of a moleculeincluding H, OH, and the like for convenience.

Impurities such as moisture existing in the oxide semiconductor layerare reduced and the oxide semiconductor layer is oxidized by the heattreatment in the oxygen atmosphere, which leads to improvement of thereliability of a thin film transistor. Further, the reliability of thethin film transistor can be improved by forming an oxide insulatinglayer so as to be in contact with the oxide semiconductor layer.

The oxide insulating layer, which is formed in contact with the oxidesemiconductor layer to which the heat treatment is performed in theoxygen atmosphere, is formed using an inorganic insulating layer, whichblocks entry of impurities such as moisture, a hydrogen ion, and OH⁻. Astypical examples of the oxide insulating layer, there are a siliconoxide layer, a silicon nitride oxide layer, and a stacked layer thereof.

After the oxide insulating layer serving as a protection layer is formedon and in contact with the oxide semiconductor layer to which the heattreatment is performed in the oxygen atmosphere, further heat treatmentmay be performed. The heat treatment after the oxide insulating layerserving as a protection layer is formed on and in contact with the oxidesemiconductor layer can reduce variation in electric characteristics ofa thin film transistor.

With the above structure, at least one of the above problems can beresolved.

One embodiment of the present invention is a method for manufacturing asemiconductor device as follows: a gate electrode layer is formed over asubstrate having an insulating surface; a gate insulating layer isformed over the gate electrode layer; an oxide semiconductor layer isformed over the gate insulating layer; the oxide semiconductor layer isdehydrated or dehydrogenated in an oxygen atmosphere; a source and drainelectrode layers are formed over the dehydrated or dehydrogenated oxidesemiconductor layer; and an oxide insulating layer which is in contactwith part of the oxide semiconductor layer is formed over the gateinsulating layer, the oxide semiconductor layer, and the source anddrain electrode layers.

Another embodiment of the present invention is a method formanufacturing a semiconductor device as follows: a gate electrode layeris formed over a substrate having an insulating surface; a gateinsulating layer is formed over the gate electrode layer; an oxidesemiconductor layer is formed over the gate insulating layer; the oxidesemiconductor layer is heated in an oxygen atmosphere; a source anddrain electrode layers are formed over the dehydrated or dehydrogenatedoxide semiconductor layer; and an oxide insulating layer which is incontact with part of the oxide semiconductor layer is formed over thegate insulating layer, the oxide semiconductor layer, and the source anddrain electrode layers. It is preferable that the oxide semiconductorlayer be heated in an oxygen atmosphere at a temperature higher than orequal to 200° C., and then slowly cooled to a range of higher than orequal to room temperature and lower than 100° C.

The oxide semiconductor used in this specification forms a thin filmexpressed by InMO₃(ZnO)_(m) (m>0), and a thin film transistor using thethin film as a semiconductor layer is manufactured. Note that M denotesone metal element or a plurality of metal elements selected from Ga, Fe,Ni, Mn, and Co. For example, M may denote Ga; or M may denote the aboveanother metal element in addition to Ga, for example Ga and Ni or Ga andFe. Further, the above oxide semiconductor may contain Fe or Ni, anothertransitional metal element, or an oxide of the transitional metal as animpurity element in addition to the metal element contained as M. Inthis specification, among the oxide semiconductor layers whosecomposition formulae are represented by InMO₃(ZnO)_(m) (m>0), an oxidesemiconductor whose composition formula includes at least Ga as M isreferred to as an In—Ga—Zn—O-based oxide semiconductor, and a thin filmof the In—Ga—Zn—O-based oxide semiconductor is referred to as anIn—Ga—Zn—O-based non-single-crystal layer.

As the oxide semiconductor applied to the oxide semiconductor layer, anyof the following oxide semiconductors can be applied besides the above:an In—Sn—Zn—O-based oxide semiconductor; an In—Al—Zn—O-based oxidesemiconductor; a Sn—Ga—Zn—O-based oxide semiconductor; anAl—Ga—Zn—O-based oxide semiconductor; a Sn—Al—Zn—O-based oxidesemiconductor; an In—Zn—O-based oxide semiconductor; a Sn—Zn—O-basedoxide semiconductor; an Al—Zn—O-based oxide semiconductor; an In—O-basedoxide semiconductor; a Sn—O-based oxide semiconductor; and a Zn—O-basedoxide semiconductor. Silicon oxide may be included in the oxidesemiconductor layer. The oxide semiconductor layer includes siliconoxide (SiO_(X) (X>0)) which suppresses crystallization of the oxidesemiconductor layer, whereby crystallization of the oxide semiconductorlayer due to heat treatment can be suppressed. It is preferable that theoxide semiconductor layer be in an amorphous state; however, the oxidesemiconductor layer may be partly crystallized.

It is preferable that the oxide semiconductor be an oxide semiconductorcontaining In, more preferably an oxide semiconductor containing In andGa. In order to obtain an I-type (intrinsic) oxide semiconductor layer,dehydration or dehydrogenation is effective.

Since a thin film transistor is easily broken by static electricity orthe like, it is preferable to provide a protective circuit forprotecting a driver circuit over the same substrate as that for a gateline or a source line. It is preferable that the protective circuit beformed with a non-linear element including an oxide semiconductor.

The gate insulating layer and the oxide semiconductor layer may besuccessively processed (the process also called successive treatment, aninsitu process, or successive film formation) without exposure to theair. Successive treatment without exposure to the air makes it possibleto obtain each an interface between the gate insulating layer and theoxide semiconductor layer, which is not contaminated by atmosphericcomponents or impurity elements floating in the air, such as moisture orhydrocarbon; accordingly, variation in characteristics of the thin filmtransistor can be reduced.

Note that the term “successive treatment” in this specification meansthat during a series of steps from a first treatment step by a plasmaCVD method or a sputtering method to a second treatment step by theplasma CVD method or the sputtering method, an atmosphere in which asubstrate to be processed is disposed is not contaminated by acontaminant atmosphere such as the air, and is kept controlled to bevacuum or an inert gas atmosphere (a nitrogen atmosphere or a rare gasatmosphere). The successive treatment enables film formation whilepreventing moisture or the like from being attached to the substrateafter cleaned.

Performing the series of steps from the first treatment step to thesecond treatment step in the same chamber is within the scope of thedefinition of the successive treatment in this specification.

In addition, the following case is also within the scope of thedefinition of the successive treatment in this specification: in thecase of performing the series of steps from the first treatment step tothe second treatment step in different chambers, the substrate istransferred after the first treatment step to another chamber withoutbeing exposed to the air and is then subjected to the second treatment.

The case where there is a substrate transfer step, an alignment step, aslow cooling step, a step of heating or cooling a substrate so that thetemperature of the substrate is suitable for the second treatment step,or the like between the first treatment step and the second treatmentstep is also in the scope of the definition of the successive treatmentin this specification.

However, the case where there is a step using liquid, such as a cleaningstep, wet etching, or resist formation may be provided between the firsttreatment step and the second treatment step is not within the scope ofthe definition of the successive treatment in this specification.

In accordance with the present invention, a thin film transistor havingstable electric characteristics can be manufactured. In accordance withthe present invention, a semiconductor device including a highlyreliable thin film transistor having better electric characteristics canbe manufactured.

BRIEF DESCRIPTION OF DRAWINGS

In the accompanying drawings:

FIGS. 1A to 1D are cross-sectional diagrams of a manufacturing processof a semiconductor device according to one embodiment of the presentinvention;

FIGS. 2A and 2B illustrate a semiconductor device according to oneembodiment of the present invention;

FIG. 3 is a cross-sectional diagram of an electric furnace;

FIGS. 4A to 4D are cross-sectional diagrams of a manufacturing processof a semiconductor device according to one embodiment of the presentinvention;

FIGS. 5A and 5B illustrate a semiconductor device according to oneembodiment of the present invention;

FIGS. 6A to 6D are cross-sectional diagrams of a manufacturing processof a semiconductor device according to one embodiment of the presentinvention;

FIGS. 7A to 7C are cross-sectional diagrams of a manufacturing processof a semiconductor device according to one embodiment of the presentinvention;

FIG. 8 illustrates a semiconductor device according to one embodiment ofthe present invention;

FIGS. 9A1 and 9A2 illustrate a semiconductor device according to oneembodiment of the present invention and FIGS. 9B1 and 9B2 illustrate asemiconductor device according to one embodiment of the presentinvention;

FIGS. 10A to 10D illustrate a manufacturing method of a semiconductordevice according to one embodiment of the present invention;

FIG. 11 illustrates a semiconductor device according to one embodimentof the present invention;

FIG. 12 illustrates a semiconductor device according to one embodimentof the present invention;

FIGS. 13A to 13C illustrate a semiconductor device according to oneembodiment of the present invention;

FIGS. 14A and 14B each illustrate a semiconductor device according toone embodiment of the present invention;

FIG. 15 illustrates a semiconductor device according to one embodimentof the present invention;

FIGS. 16A and 16B each illustrate a block diagram of a display device;

FIGS. 17A and 17B illustrate a structure of a signal line drivercircuit;

FIGS. 18A to 18C are circuit diagrams illustrating a structure of ashift resistor;

FIGS. 19A and 19B illustrate an operation of a shift resistor;

FIGS. 20A1, 20A2, and 20B each illustrate a semiconductor deviceaccording to one embodiment of the present invention;

FIG. 21 illustrates a semiconductor device according to one embodimentof the present invention;

FIG. 22 illustrates a semiconductor device according to one embodimentof the present invention;

FIG. 23 illustrates an equivalent circuit of a pixel of a semiconductordevice according to one embodiment of the present invention;

FIGS. 24A to 24C each illustrate a semiconductor device according to oneembodiment of the present invention;

FIGS. 25A and 25B illustrate a semiconductor device according to oneembodiment of the present invention;

FIG. 26 is an external view illustrating an example of an electronicbook reader;

FIGS. 27A and 27B are external views illustrating an example of atelevision set and an example of a digital photo frame, respectively;

FIGS. 28A and 28B are external views illustrating examples of anamusement machine;

FIGS. 29A and 29B are external views illustrating an example of aportable computer and an example of a mobile phone, respectively;

FIGS. 30A and 30B show results of a simulation of an interaction of anoxygen molecule and a surface of an oxide semiconductor layer;

FIG. 31 illustrates a structure of an oxide semiconductor layer used fora calculation;

FIG. 32 is a graph showing measurement results of the oxygen density ofthe oxide semiconductor layer; and

FIGS. 33A to 33C illustrate an interaction of oxygen and a surface of anoxide semiconductor layer.

BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, embodiments and an example of the present invention will bedescribed in detail with reference to the accompanying drawings. It isto be noted that the present invention is not limited to the descriptionbelow, and it is easily understood by those skilled in the art thatmodes and details disclosed herein can be modified in various wayswithout departing from the spirit and scope of the present invention.Therefore, the present invention is not construed as being limited tothe description of the embodiments and example.

Embodiment 1

A semiconductor device and a method for manufacturing the semiconductordevice will be described with reference to FIGS. 1A to 1D and FIGS. 2Aand 2B.

FIG. 2A is a plan view of a thin film transistor 470 included in asemiconductor device, and FIG. 2B is a cross-sectional diagram alongline C₁-C₂ of FIG. 2A. The thin film transistor 470 is a bottom-gatethin film transistor and includes, over a substrate 400 which is asubstrate having an insulating surface, a gate electrode layer 401, agate insulating layer 402, an oxide semiconductor layer 403, and asource and drain electrode layers 405 a and 405 b. In addition, an oxideinsulating layer 407 is provided to cover the thin film transistor 470and be in contact with the oxide semiconductor layer 403.

As for the oxide semiconductor layer 403, heat treatment which reducesimpurities such as moisture (heat treatment for dehydration ordehydrogenation) is performed in an oxygen atmosphere at least after theformation of the oxide semiconductor layer. The oxide semiconductorlayer 403 after being subjected to the heat treatment is used as achannel formation region of a thin film transistor, so that thereliability of the thin film transistor can be improved.

Further, after the impurities such as moisture (H₂O) are eliminated andthe oxide semiconductor layer 403 is oxidized by the heat treatment(heat treatment for dehydration or dehydrogenation) in the oxygenatmosphere, it is preferable to perform slow cooling in the/an oxygenatmosphere or in an inert gas atmosphere. Furthermore, it is preferableto perform the formation of the oxide insulating layer to be in contactwith the oxide semiconductor layer, and the like after the heattreatment for dehydration or dehydrogenation and the slow cooling. Inthis manner, the reliability of the thin film transistor 470 can beimproved.

It is preferable that impurities such as moisture be reduced not only inthe oxide semiconductor layer 403 but also in the gate insulating layer402 and in an interface between the oxide semiconductor layer and alayer that is provided over/under and in contact with the oxidesemiconductor layer 403, that is, an interface between the gateinsulating layer 402 and the oxide semiconductor layer 403 and aninterface between the oxide insulating layer 407 and the oxidesemiconductor layer 403.

Note that the source and drain electrode layers 405 a and 405 b that arein contact with the oxide semiconductor layer 403 are formed using oneor more materials selected from titanium, aluminum, manganese,magnesium, zirconium, beryllium, and thorium. An alloy film or alloyfilms including any combination of the above elements may be stacked.

The oxide semiconductor layer 403 including a channel formation regionis formed using an oxide material having semiconductor characteristics;typically, an In—Ga—Zn—O-based non-single-crystal layer is used.

FIGS. 1A to 1D are cross-sectional diagrams illustrating a manufacturingprocess of the thin film transistor 470 show in FIGS. 2A and 2B.

In FIG. 1A, the gate electrode layer 401 is provided over the substrate400 which is a substrate having an insulating surface.

Although there is no particular limitation on the substrate 400, it isnecessary that the substrate have heat resistance high enough to resistheat treatment to be performed later. As the substrate 400, a glasssubstrate of barium borosilicate glass, aluminoborosilicate glass, orthe like can be used.

Further, in the case where a substrate having a light-transmittingproperty is used as the substrate 400, it is preferable to use onehaving a strain point higher than or equal to 730° C. in the case wherethe temperature of the heat treatment performed later is high. Further,as a material of the substrate 100, for example, a glass material suchas aluminosilicate glass, aluminoborosilicate glass, or bariumborosilicate glass is used. By containing a larger amount of bariumoxide (BaO) than boric acid, a glass becomes heat-resistant and of morepractical use. Therefore, it is preferable to use a glass substratecontaining BaO and B₂O₃ so that the amount of BaO is larger than that ofB₂O₃.

A substrate formed of an insulator, such as a ceramic substrate, aquartz substrate, or a sapphire substrate may be used as the substrate400. Alternatively, crystallized glass or the like may be used.

An insulating layer serving as a base layer may be provided between thesubstrate 400 and the gate electrode layer 401. The base film has afunction of preventing diffusion of an impurity element from thesubstrate 400, and can be formed to have a single-layer or stacked-layerstructure using one or more of a silicon nitride layer, a silicon oxidelayer, a silicon nitride oxide layer, and a silicon oxynitride layer.

The gate electrode layer 401 can be formed using a single layer or astacked layer using a metal material such as molybdenum, titanium,chromium, tantalum, tungsten, aluminum, copper, neodymium, or scandium,or an alloy material which includes any of these materials as a maincomponent.

For example, as a stacked structure of two layers of the gate electrodelayer 401, any of the following structures is preferable: a two-layerstructure in which a molybdenum layer is stacked over an aluminum layer,a two-layer structure in which a molybdenum layer is stacked over acopper layer, a two-layer structure in which a titanium nitride layer ora tantalum nitride layer is stacked over a copper layer, and a two-layerstructure in which a titanium nitride layer and a molybdenum layer arestacked. As a stacked structure of three layers, it is referable to usea stacked layer of a tungsten layer or a tungsten nitride layer, analloy layer of aluminum and silicon or an alloy layer of aluminum andtitanium, and a titanium nitride layer or a titanium layer.

Next, the gate insulating layer 402 is formed over the gate electrodelayer 401.

The gate insulating layer 402 can be formed using a single layer or astacked layer of a silicon oxide layer, a silicon nitride layer, asilicon oxynitride layer, a silicon nitride oxide layer, an aluminumoxide layer, and/or a tantalum oxide layer by a plasma CVD method, asputtering method, or the like. For example, a silicon oxynitride layermay be formed by a plasma CVD method using a deposition gas containingsilane (SiH₄), oxygen, and nitrogen.

Next, the oxide semiconductor layer is formed over the gate insulatinglayer 402.

Note that before the oxide semiconductor film is formed by a sputteringmethod, it is preferable to perform reverse sputtering in which an argongas is introduced and plasma is generated so that dust on a surface ofthe gate insulating layer 402 is removed. The reverse sputtering is amethod in which voltage is applied to a substrate, not to a target side,in an argon atmosphere by using an RF power supply and plasma isgenerated in the vicinity of the substrate to modify a surface of thesubstrate. Note that as well as argon, helium, or the like may be used.

The oxide semiconductor film is formed by a sputtering method with useof an In—Ga—Zn—O based oxide semiconductor target. The oxidesemiconductor layer is formed by a sputtering method using anIn—Ga—Zn—O-based oxide semiconductor target. The sputtering method iscarried out in a rare gas (typically argon) atmosphere, an oxygenatmosphere, or an atmosphere including a rare gas (typically argon) andoxygen.

The gate insulating layer 402 and the oxide semiconductor layer may beformed successively without exposure to the air. Successive filmformation without exposure to the air makes it possible to obtain eachinterface between stacked layers, which is not contaminated byatmospheric components or impurity elements floating in the air, such asmoisture or hydrocarbon; accordingly, variation in characteristics ofthe thin film transistor can be reduced.

The oxide semiconductor layer is processed into an island shape througha photolithography process, thereby forming an oxide semiconductor layer430 (see FIG. 1A).

Next, it is preferable that heat treatment be performed on the oxidesemiconductor layer in an oxygen atmosphere and then slow cooling beperformed in an oxygen atmosphere or an inert gas atmosphere. The heattreatment performed on the oxide semiconductor layer 430 in the aboveatmosphere can eliminate impurities such as hydrogen and moistureexisting in the oxide semiconductor layer 430 and oxidize the oxidesemiconductor layer 430, so that an oxide semiconductor layer 431 isobtained (see FIG. 1B). The oxide semiconductor layer 430 may becrystallized to be a microcrystalline layer or a polycrystalline layer,which depends on the condition of the heat treatment or a material ofthe oxide semiconductor layer.

The oxygen atmosphere refers to an atmosphere of a gas containing anoxygen atom, typically refers to an atmosphere of oxygen, ozone, or anitrogen oxide (such as nitrogen monoxide, nitrogen dioxide, dinitrogenmonoxide, dinitrogen trioxide, dinitrogen tetraoxide, or dinitrogenpentoxide). The oxygen atmosphere may contain an inert gas of nitrogenor a rare gas (such as helium or argon); in that case, the amount of theinert gas is less than that of the gas containing an oxygen atom.

It is preferable that moisture, hydrogen, and the like be not includedin the oxygen atmosphere in the heat treatment. Alternatively, it ispreferable that the purity of oxygen introduced into a heat treatmentapparatus be 6N (99.9999%) or higher, more preferably 7N (99.99999%) orhigher (that is, the concentration of impurities be 1 ppm or lower, morepreferably 0.1 ppm or lower).

The heat treatment can be performed by a heating method using anelectric furnace or an instantaneous heating method such as a gas rapidthermal anneal (GRTA) method using a heated gas or a lamp rapid thermalanneal (LRTA) method using a lamp light.

Here, as one mode of the heat treatment on the oxide semiconductor layer430, a heating method using an electric furnace 601 is described withreference to FIG. 3

FIG. 3 is a schematic view of the electric furnace 601. A heater 603 isprovided outside a chamber 602 and used for heating the chamber 602. Asusceptor 605 on which a substrate 604 is mounted is provided in thechamber 602, and the substrate 604 is carried into or out of the chamber602. Further, the chamber 602 is provided with a gas supply means 606and an evacuation means 607. A gas is introduced into the chamber 602 bythe gas supply means 606. The evacuation means 607 evacuates the chamber602. Note that the temperature-rise characteristics of the electricfurnace 601 are preferably set at higher than or equal to 0.1° C./minand lower than or equal to 20° C./min. In addition, the temperature-dropcharacteristics of the electric furnace 601 are preferably set at higherthan or equal to 0.1° C./min and lower than or equal to 15° C./min.

The gas supply means 606 includes a gas supply source 611, a pressureadjusting valve 612, a refiner 613, a mass flow controller 614, and astop valve 615. In this embodiment, the refiner 613 is provided betweenthe gas supply source 611 and the chamber 602. With the refiner 613,impurities such as moisture or hydrogen in a gas which is introducedinto the chamber 602 from the gas supply source 611 can be removed, sothat entry of impurities such as moisture and hydrogen into the chamber602 can be suppressed.

In this embodiment, a gas including an oxygen atom is introduced intothe chamber 602 from the gas supply source 611 so that the atmosphere inthe chamber becomes an oxygen atmosphere, and the oxide semiconductorlayer 430 which is formed over the substrate 604 is heated in thechamber 602 heated to a temperature higher than or equal to 200° C. andlower than the strain point, preferably higher than or equal to 400° C.and lower than or equal to 700° C. In this manner, dehydration ordehydrogenation of the oxide semiconductor layer 430 can be performed.

According to this embodiment, the oxide semiconductor layer 430 is madeto be less-defective i-type by the heat treatment for dehydration ordehydrogenation in the oxygen atmosphere since the surface of the oxidesemiconductor layer 430 can be oxidized and oxygen is bounded to adefect or a part from which the impurities such as moisture and hydrogenare detached. Accordingly, by using the dehydrated or dehydrogenatedoxide semiconductor layer 430 as a channel formation region, thereliability of a thin film transistor to be formed can be improved.

The heat treatment condition is set such that at least one of two peaksof water, which appears at around 300° C. is not detected even when TDS(Thermal Desorption Spectroscopy) measurement is performed on the oxidesemiconductor layer after being dehydrated or dehydrogenated, to 450° C.Therefore, even when TDS measurement is performed on a thin filmtransistor including the dehydrated or dehydrogenated oxidesemiconductor layer to, 450° C., the peak of water which appears ataround 300° C. is not detected.

Next, it is preferable that the heater be turned off, the chamber 602 ofthe heat apparatus be held in the/an oxygen atmosphere or an inert gasatmosphere, and slow cooling be performed. For example, slow cooling maybe performed from the temperature of the heat treatment to a temperaturehigher than or equal to room temperature and lower than 100° C. afterthe heat treatment. Consequently, the reliability of a thin filmtransistor to be formed can be improved.

In the cooling step, the temperature may be decreased from the heattemperature T, for the dehydration or dehydrogenation of the oxidesemiconductor layer 430 to a temperature which is low enough to prevententry of water, specifically a temperature that is lower than the heattemperature T by 100° C. or higher.

The substrate 604 in the chamber 602 of the heat apparatus may be cooledto a temperature lower than 300° C., and then, the substrate 604 may betransferred into an oxygen atmosphere or an inert gas atmosphere at atemperature higher than or equal to room temperature and lower than 100°C.; accordingly, the cooling time of period of the substrate 604 can bereduced.

When the heat apparatus has a plurality of chambers, the heat treatmentand the cooling treatment can be performed in different chambers.Typically, in a first chamber which is heated to a temperature higherthan or equal to 200° C. and lower than the strain point of thesubstrate, preferably higher than or equal to 400° C. and lower than orequal to 700° C., the oxide semiconductor layer 430 formed over thesubstrate is heated in an oxygen atmosphere. Next, the substrate onwhich the above heat treatment is performed is transferred, through atransfer chamber in an oxygen atmosphere or an inert gas atmosphere, toa second chamber whose temperature is higher than or equal to roomtemperature and lower than 100° C. and is subjected to cooling treatmentin an oxygen atmosphere or an inert gas atmosphere. Through the aboveprocess, throughput can be improved.

The oxide semiconductor layer may be subjected to the heat treatment inthe oxygen atmosphere before processed into the island-shaped oxidesemiconductor layer. In that case, after the heat treatment of the oxidesemiconductor layer in the oxygen atmosphere or in an inert gasatmosphere, slow cooling to a temperature higher than or equal to roomtemperature and lower than 100° C. is performed, the substrate is takenout of the heat apparatus, and a photolithography process is performedon the substrate.

The oxide semiconductor layer 431 after the heat treatment in the oxygenatmosphere is preferably in an amorphous state, but may be partlycrystallized.

Next, a conductive layer is formed over the gate insulating layer 402and the oxide semiconductor layer 431.

As examples of a material of the conductive layer, there are thefollowing: an element selected from Al, Cr, Ta, Ti, Mo, and W; an alloycontaining any of the above elements as its component; an alloy layercontaining a combination of any of the above elements; and the like.

In the case where heat treatment is performed after the formation of theconductive layer, it is preferable that the conductive layer have heatresistance enough to withstand this heat treatment. Since aluminum (Al)has disadvantages such as low heat resistance and a tendency ofeasy-to-corrode, Al is used in combination with a heat-resistantconductive material. As the heat-resistant conductive material which isused in combination with Al, any of the following materials may be used:an element selected from titanium (Ti), tantalum (Ta), tungsten (W),molybdenum (Mo), chromium (Cr), neodymium (Nd), and scandium (Sc); analloy containing any of the above elements as its component; an alloylayer containing a combination of any of the above elements; and anitride containing any of the above elements as its component.

The oxide semiconductor layer 431 and the conductive layer are etched inan etching step to form the oxide semiconductor layer 403 and the sourceand drain electrode layers 405 a and 405 b (see FIG. 1C). Note that onlypart of the oxide semiconductor layer 431 is etched, so that the oxidesemiconductor layer 403 has a groove (a depressed portion).

The oxide insulating layer 407 is formed so as to be in contact with theoxide semiconductor layer 403. The oxide insulating layer 407 can have athickness greater than or equal to 1 nm and can be formed by a method bywhich impurities such as moisture or hydrogen do not enter the oxideinsulating layer 407 as much as possible, such as a CVD method or asputtering method. In this embodiment, a sputtering method is used toform the oxide insulating layer 407. It is preferable that the oxideinsulating layer 407, which is formed to be in contact with thedehydrated or dehydrogenated oxide semiconductor layer, be formed usingan inorganic insulating layer which includes moisture, a hydrogen ion,OH⁻, and the like as less as possible and blocks entry of them from theoutside; specifically, a single layer of a silicon oxide layer or asilicon oxynitride layer, or a stacked layer thereof may be used.

A silicon oxide layer with a thickness of 300 nm is formed as the oxideinsulating layer 407 in this embodiment. The substrate temperature atthe time of film formation may be set to higher than or equal to roomtemperature and lower than or equal to 300° C., and is 100° C. in thisembodiment. The formation of the oxide insulating layer 407 by thesputtering method can be performed in an atmosphere of the following: arare gas (typically argon), oxygen, or a mixture of a rare gas(typically argon) and oxygen. A silicon oxide target or a silicon targetmay be used as a target thereof. For example, a silicon oxide film canbe formed by a sputtering method using a silicon target in an atmosphereof oxygen and nitrogen.

The oxide insulating layer 407 is formed by a sputtering method, a PCVDmethod, or the like so as to be in contact with the dehydrated ordehydrogenated oxide semiconductor layer 430; in this manner, the highlyreliable thin film transistor 470 can be manufactured (see FIG. 1D).

It is preferable that after impurities such as H₂O, H, or OH included inthe oxide semiconductor layer are reduced by the above heat treatmentfor dehydration or dehydrogenation in the oxygen atmosphere, slowcooling be performed. Further, the formation of the oxide insulatinglayer so as be in contact with the oxide semiconductor layer, and thelike may be performed after the slow cooling; accordingly, thereliability of the thin film transistor 470 can be improved.

Further, after the oxide insulating layer 407 is formed, the thin filmtransistor 470 may be subjected to heat treatment (preferably at atemperature higher than or equal to 150° C. and lower than 350° C.) inan oxygen atmosphere or an inert atmosphere. For example, heat treatmentis performed at 250° C. for 1 hour in a nitrogen atmosphere. By the heattreatment, the oxide semiconductor layer 403 is heated while being incontact with the oxide insulating layer 407; accordingly, variation inelectric characteristics of the thin film transistor 470 can be reduced.There is no particular limitation on this heat treatment (preferably atthe temperature higher than or equal to 150° C. and lower than 350° C.)as long as it is performed after the formation of the oxide insulatinglayer 407. The heat treatment can be performed without increase in thenumber of steps by serving also heat treatment in another step such asheat treatment in formation of a resin layer or heat treatment forreducing the resistance of a transparent conductive layer.

Embodiment 2

A semiconductor device and a method for manufacturing the semiconductordevice will be described with reference to FIGS. 4A to 4D and FIGS. 5Aand 5B. Embodiment 1 can be applied to the same portion(s), or aportion(s) or a step(s) having the similar function(s) as/to Embodiment1, and the description thereof is not repeated.

FIG. 5A is a plan view of a thin film transistor 460 included in asemiconductor device, and FIG. 5B is a cross-sectional diagram alongline D1-D2 of FIG. 5A. The thin film transistor 460 is a bottom-gatethin film transistor and includes, over a substrate 450 which is asubstrate having an insulating surface, a gate electrode layer 451, agate insulating layer 452, a source and drain electrode layers 455 a and455 b, and an oxide semiconductor layer 453. In addition, an oxideinsulating layer 457 is provided to cover the thin film transistor 460and be in contact with the oxide semiconductor layer 453.

In the thin film transistor 460, the gate insulating layer 452 existsthroughout the region including the thin film transistor 460, and thegate electrode layer 451 is provided between the gate insulating layer452 and the substrate 450 which is a substrate having an insulatingsurface. The source and drain electrode layers 455 a and 455 b areprovided over the gate insulating layer 452. Further, the oxidesemiconductor layer 453 is provided over the gate insulating layer 452and the source and drain electrode layers 455 a and 455 b. Although notshown, a wiring layer is provided over the gate insulating layer 452 inaddition to the source and drain electrode layers 455 a and 455 b, andthe wiring layer extends beyond the peripheral portion of the oxidesemiconductor layer 453.

The oxide semiconductor layer 453 is subjected to heat treatment whichreduces impurities such as moisture or hydrogen (heat treatment fordehydration or dehydrogenation) in an oxygen atmosphere at least afterthe formation of the oxide semiconductor layer. Accordingly, thereliability of the thin film transistor can be improved.

After impurities such as moisture (H₂O) are eliminated by the heattreatment for dehydration or dehydrogenation, it is preferable that theoxide semiconductor layer be slowly cooled in the/an oxygen atmosphereor an inert gas atmosphere. It is preferable to perform the formation ofthe oxide insulating layer to be in contact with the oxide semiconductorlayer, and the like after the heat treatment for dehydration ordehydrogenation and the slow cooling; accordingly, the reliability ofthe thin film transistor 460 can be improved.

Then, the source and drain electrode layers 455 a and 455 b which are incontact with the oxide semiconductor layer 453 can be formed in asimilar manner to that of the source and drain electrode layers 405 aand 405 b described in Embodiment 1.

FIGS. 4A to 4D are cross-sectional diagrams illustrating a process formanufacturing the thin film transistor 460.

The gate electrode layer 451 is provided over the substrate 450 which isa substrate having an insulating surface. An insulating layer serving asa base layer may be provided between the substrate 450 and the gateelectrode layer 451. The base layer has a function of preventingdiffusion of an impurity element from the substrate 450, and can beformed to have a single-layer or stacked-layer structure using one ormore of a silicon nitride layer, a silicon oxide layer, a siliconnitride oxide layer, and a silicon oxynitride layer. The gate electrodelayer 451 can be formed in a similar manner to that of the gateelectrode layer 401 described in Embodiment 1.

The gate insulating layer 452 is formed over the gate electrode layer451.

The gate insulating layer 452 can be formed in a similar manner to thatof the gate insulating layer 402 described in Embodiment 1.

A conductive layer is formed over the gate insulating layer 452 andprocessed into the island-shaped source and drain electrode layers 455 aand 455 b by a photolithography process (see FIG. 4A).

The source and drain electrode layers 455 a and 455 b can be formed in asimilar manner to that of the source and drain electrode layers 405 aand 405 b described in Embodiment 1.

Next, an oxide semiconductor layer is formed over the gate insulatinglayer 452 and the source and drain electrode layers 455 a and 455 b, andprocessed into an island-shaped oxide semiconductor layer 483 (firstoxide semiconductor layer) by a photolithography process (see FIG. 4B).

The oxide semiconductor layer 483 serves as a channel formation regionand is thus formed in a manner similar to the oxide semiconductor layerdescribed in Embodiment 1.

Before the oxide semiconductor layer 483 is formed by a sputteringmethod, it is preferable to perform reverse sputtering in which an argongas is introduced and plasma is generated so that dust on a surface ofthe gate insulating layer 452 is removed.

After the heat treatment for dehydration or dehydrogenation is performedon the oxide semiconductor layer 483, it is preferable that the oxidesemiconductor layer be slowly cooled in the/an oxygen atmosphere or aninert gas atmosphere. As the heat treatment for dehydration ordehydrogenation, heat treatment at a temperature higher than or equal to200° C. and lower than the strain point of the substrate, preferablyhigher than or equal to 400° C. and lower than or equal to 700° C. isperformed in an oxygen atmosphere. Through the above process, thedehydrated or dehydrogenated oxide semiconductor layer 483 (a secondoxide semiconductor layer) can be formed (see FIG. 4C).

It is preferable that moisture, hydrogen, and the like be not includedin the oxygen atmosphere in the heat treatment for dehydration ordehydrogenation. Alternatively, it is preferable that the purity of agas containing an oxygen atom, nitrogen, or a rare gas such as helium,neon, or argon introduced into a heat treatment apparatus be 6N(99.9999%) or higher, more preferably 7N (99.99999%) or higher (that is,the concentration of impurities be 1 ppm or lower, more preferably 0.1ppm or lower).

The oxide semiconductor layer may be subjected to the heat treatment inthe oxygen atmosphere before processed into the island-shaped oxidesemiconductor layer. In that case, after the heat treatment of the oxidesemiconductor layer in the oxygen atmosphere, it is preferable toperform slow cooling to a temperature higher than or equal to roomtemperature and lower than 100° C. Then, the substrate is taken out ofthe heat apparatus, and a photolithography process is performed on thesubstrate.

The oxide semiconductor layer 453 after the heat treatment in the oxygenatmosphere is preferably in an amorphous state, but may be partlycrystallized.

Next, an oxide insulating layer 457 is formed so as to be in contactwith the oxide semiconductor layer 403 by a sputtering method or a PCVDmethod. In this embodiment, a silicon oxide layer with a thickness of300 nm formed as the oxide insulating layer 457. The substratetemperature at the time of film formation may be set to higher than orequal to room temperature and lower than or equal to 300° C., and is100° C. in this embodiment. The oxide insulating layer 457 which is thesilicon oxide layer is formed so as to be in contact with the dehydratedor dehydrogenated oxide semiconductor layer 453. In the process formanufacturing a semiconductor device, heat treatment for dehydration ordehydrogenation in an oxygen atmosphere, slow cooling in the/an oxygenatmosphere or an inert gas atmosphere, the formation of the oxideinsulating layer, and the like are performed; in this manner, the thinfilm transistor 460 can be manufactured (see FIG. 4D).

Further, after the oxide insulating layer 457 which is a silicon oxidelayer is formed, the thin film transistor 460 may be subjected to heattreatment (preferably at a temperature higher than or equal to 150° C.and lower than 350° C.) in an oxygen atmosphere or an inert atmosphere.For example, heat treatment is performed at 250° C. for 1 hour in anitrogen atmosphere. By the heat treatment, the oxide semiconductorlayer 453 is heated while being in contact with the oxide insulatinglayer 457; accordingly, variation in electric characteristics of thethin film transistor 460 can be reduced. There is no particularlimitation on this heat treatment (preferably at the temperature higherthan or equal to 150° C. and lower than 350° C.) as long as it isperformed after the formation of the oxide insulating layer 457. Theheat treatment can be performed without increase in the number of stepsby serving also heat treatment in another step such as heat treatment information of a resin layer or heat treatment for reducing the resistanceof a transparent conductive layer.

Embodiment 2 can be combined with Embodiment 1 as appropriate.

Embodiment 3

A process for manufacturing a semiconductor device including a thin filmtransistor will be described with reference to FIGS. 6A to 6D, FIGS. 7Ato 7C, 8, and 9A1, 9A2, 9B1, and 9B2.

In FIG. 6A, as a substrate 100 having light-transmitting property, thesubstrate 100 described in Embodiment 1 can be used as appropriate.

Next, a conductive layer is formed entirely over a surface of thesubstrate 100, and then a first photolithography process is performed toform a resist mask. Then, an unnecessary portion is removed by etching,so that wirings and electrodes (a gate wiring including a gate electrodelayer 101, a capacitor wiring 108, and a first terminal 121) are formed.At this time, the etching is performed so that at least end portions ofthe gate electrode layer 101 are tapered.

The gate wiring including the gate electrode layer 101, the capacitorwiring 108, and the first terminal 121 in a terminal portion each can beformed using a material of the gate electrode layer 401 described inEmbodiment 1. As a conductive material having heat resistance is used toform the gate electrode layer 101, any of the following is used: anelement selected from titanium (Ti), tantalum (Ta), tungsten (W),molybdenum (Mo), chromium (Cr), neodymium (Nd), and scandium (Sc); analloy layer containing any of these elements as its component; an alloycontaining a combination of any of these elements; or nitride containingany of these elements as its component.

Next, a gate insulating layer 102 is formed over an entire surface ofthe gate electrode layer 101. The gate insulating layer 102 can beformed in a similar manner to that of the gate insulating layer 402described in Embodiment 1. The thickness of the gate insulating layer102 is 50 nm to 250 nm.

For example, as the gate insulating layer 402, a silicon oxide layer isformed to a thickness of 100 nm by a sputtering method.

Next, an oxide semiconductor layer (an In—Ga—Zn—O-basednon-single-crystal layer) is formed over the gate insulating layer 102.It is effective to deposit the In—Ga—Zn—O based non-single-crystal layerwithout exposure to the air after the formation of the gate insulatinglayer 102 because dust and moisture are not attached to the interfacebetween the gate insulating layer and the semiconductor layer. In thisembodiment, the oxide semiconductor layer is formed in an atmospherecontaining oxygen, argon, or a combination of oxygen and argon under thecondition where a target is an oxide semiconductor target containing In,Ga, and Zn (In—Ga—Zn—O-based oxide semiconductor target(In₂O₃:Ga₂O₃:ZnO=1:1:1)) with a diameter of 8 inches, the distancebetween the substrate and the target is 170 mm, the pressure is 0.4 Pa,and the direct current (DC) power supply is 0.5 kW. It is preferable touse a pulsed direct-current (DC) power source with which dust can bereduced and thickness distribution can be evened. The In—Ga—Zn—O-basednon-single-crystal layer is formed to have a thickness of 5 nm to 200nm. As the oxide semiconductor layer, an In—Ga—Zn—O-basednon-single-crystal film with the thickness of 50 nm is formed using theIn—Ga—Zn—O-based oxide semiconductor target by a sputtering method.

Examples of the sputtering method include an RF sputtering method inwhich a high-frequency power source is used for a sputtering powersource, a DC sputtering method using a DC power source, and a pulsed DCsputtering method in which a bias is applied in a pulsed manner using aDC power source. An RF sputtering method is mainly used in the casewhere an insulating layer is formed, and a DC sputtering method ismainly used in the case where a metal layer is formed.

A multi-source sputtering apparatus in which a plurality of targets ofdifferent materials can be set can be used. With the multi-sourcesputtering apparatus, layers of different materials can be deposited tobe stacked in the same chamber, or a plurality of kinds of materials canbe deposited by electric discharge at the same time in the same chamber.

A sputtering apparatus provided with a magnet system inside the chamberand used for a magnetron sputtering method, or a sputtering apparatusused for an ECR sputtering method in which plasma generated with the useof microwaves is used without using glow discharge can be used.

Further, as the deposition method using the sputtering method, there arealso a reactive sputtering method in which a target substance and asputtering gas component are chemically reacted with each other duringdeposition to form a thin compound layer thereof, and a bias sputteringmethod in which voltage is also applied to a substrate duringdeposition.

Next, a second photolithography process is performed to form a resistmask, and the oxide semiconductor layer is etched. For example,unnecessary portions thereof are removed by wet etching using a mixedsolution of phosphoric acid, acetic acid, and nitric acid, so that anoxide semiconductor layer 133 is formed (see FIG. 6A). The etching hereis not limited to wet etching; dry etching may be performed as well.

As an etching gas for the dry etching, a gas containing chlorine(chlorine-based gas such as chlorine (Cl₂), boron chloride (BCl₃),silicon chloride (SiCl₄), or carbon tetrachloride (CCl₄)) is preferablyused.

Alternatively, any of the following can be used: a gas containingfluorine (fluorine-based gas such as carbon tetrafluoride (CF₄), sulfurfluoride (SF₆), nitrogen fluoride (NF₃), or trifluoromethane (CHF₃));hydrogen bromide (HBr); oxygen (O₂); any of these gases to which a raregas such as helium (He) or argon (Ar) is added; and the like.

As the dry etching method, a parallel plate RIE (reactive ion etching)method or an ICP (inductively coupled plasma) etching method can beused. In order to etch the layer into a desired shape, the etchingcondition (the amount of electric power applied to a coil-shapedelectrode, the amount of electric power applied to an electrode on asubstrate side, the temperature of the electrode on the substrate side,or the like) is adjusted as appropriate.

As an etchant used for the wet etching, a solution obtained by mixingphosphoric acid, acetic acid, and nitric acid or the like can be used.ITO07N (produced by KANTO CHEMICAL CO., INC.) may be used.

Furthermore, the etchant after the wet etching is removed together withthe etched material by cleaning. The waste liquid including the etchantand the material etched off may be purified and the material may bereused. Collecting and reusing of a material such as indium included inthe oxide semiconductor layer from the waste liquid after the etchingenable efficient use of the resources and cost reduction.

The etching conditions (such as an etchant, etching period of time, andtemperature) are adjusted as appropriate depending on the material sothat the material can be etched into an appropriate shape.

Next, heat treatment for dehydration or dehydrogenation is performed onthe oxide semiconductor layer 133. It is preferable that the oxidesemiconductor layer 133 be slowly cooled in an oxygen atmosphere or aninert gas atmosphere after the heat treatment in the/an oxygenatmosphere.

The heat treatment is performed at a temperature higher than or equal to200° C. and lower than the strain point of the substrate, preferablyhigher than or equal to 400° C. and lower than or equal to 700° C. Forexample, heat treatment at 450° C. for one hour in an oxygen atmosphere,so that an oxide semiconductor layer 134 is obtained (see FIG. 6B).

Next, a conductive layer 132 is formed using a metal material over theoxide semiconductor layer 134 by a sputtering method or a vacuumevaporation method (see FIG. 6C).

As a material of the conductive layer 132, the same material as thematerial of the source and drain electrode layers 405 a and 405 bdescribed in Embodiment 1 can be used as appropriate.

In the case where heat treatment is performed after the formation of theconductive layer 132, it is preferable that the conductive layer haveheat resistance high enough to resist this heat treatment.

Next, a third photolithography process is performed to form a resistmask and then an unnecessary portion thereof is removed by etching, sothat a source and drain electrode layers 105 a and 105 b and a secondterminal 122 are formed (see FIG. 6D). Wet etching or dry etching isemployed as an etching method at this time. For example, when analuminum layer or an aluminum-alloy layer is used as the conductivelayer 132, wet etching using a mixed solution of phosphoric acid, aceticacid, and nitric acid can be performed. Alternatively, the conductivelayer 132 may be wet-etched using an ammonia peroxide mixture (hydrogenperoxide:ammonia:water=5:2:2) to form the source and drain electrodelayers 105 a and 105 b. In this etching step, an exposed region of theoxide semiconductor layer 134 is partly etched; consequently, an oxidesemiconductor layer 103 is obtained. Therefore, a region of the oxidesemiconductor layer 103 between the source and drain electrode layers105 a and 105 b has a small thickness. In FIG. 6D, the etching forforming the source and drain electrode layers 105 a and 105 b and theoxide semiconductor layer 103 is performed at a time by dry etching;accordingly, an end portion of the source or drain electrode layer 105 aand an end portion of the source or drain electrode layer 105 b arealigned with end portions of the oxide semiconductor layer 103 to becontinuous.

In this third photolithography step, the second terminal 122 which isformed of the same material as the source and drain electrode layers 105a and 105 b is left in a terminal portion. The second terminal 122 iselectrically connected to a source wiring (including the source anddrain electrode layers 105 a and 105 b).

By use of a resist mask having regions with plural thicknesses(typically, two levels of thickness) which is formed using a multi-tonemask, the number of resist masks can be reduced, resulting in simplifiedprocess simplification and cost reduction.

Next, the resist mask is removed to form an oxide insulating layer 107so as to cover the gate insulating layer 102, the oxide semiconductorlayer 103, and the source and drain electrode layers 105 a and 105 b. Asilicon oxynitride layer formed by a PCVD method is used as the oxideinsulating layer 407. The substrate temperature at the time of the filmformation of the oxide insulating layer 107 may be set to higher than orequal to room temperature and lower than or equal to 300° C., and is100° C. in this embodiment. The silicon oxynitride layer which is theoxide insulating layer 107 is provided so as to be in contact with theexposed region of the oxide semiconductor layer 103 between the sourceand drain electrode layers 105 a and 105 b; accordingly, a highlyreliable thin film transistor can be manufactured (see FIG. 7A).

Next, heat treatment may be performed after the oxide insulating layer107 is formed. The heat treatment may be performed at a temperaturehigher than or equal to 150° C. and lower than 350° C. in an oxygenatmosphere or a nitrogen atmosphere. By the heat treatment, the oxidesemiconductor layer 103 is heated while being in contact with the oxideinsulating layer 107; accordingly, the electric characteristics of athin film transistor can be improved and variation in the electriccharacteristics of the same can be reduced. There is no particularlimitation on this heat treatment (preferably at the temperature higherthan or equal to 150° C. and lower than 350° C.) as long as it isperformed after the formation of the oxide insulating layer 407. Theheat treatment can be performed without increase in the number of stepsby serving also heat treatment in another step such as heat treatment information of a resin layer or heat treatment for reducing the resistanceof a transparent conductive layer.

Through the above process, a thin film transistor 170 can bemanufactured.

Next, a fourth photolithography step is performed to form a resist mask.The oxide insulating layer 107 and the gate insulating layer 102 areetched to form a contact hole 125 that reaches the source or drainelectrode layer 105 b. In addition, a contact hole 127 that reaches thesecond terminal 122 and a contact hole 126 that reaches the firstterminal 121 are also formed in the same etching step. FIG. 7B is across-sectional diagram at this stage.

Next, the resist mask is removed, and a transparent conductive layer isformed. The transparent conductive layer is formed using indium oxide(In₂O₃), indium oxide—tin oxide alloy (In₂O₃—SnO₂, abbreviated as ITO),or the like by a sputtering method, a vacuum evaporation method, or thelike. Such a material is etched with a hydrochloric acid-based solution.However, since a residue is easily generated particularly in etchingITO, indium oxide-zinc oxide alloy (In₂O₃—ZnO) may be used to improveetching processability. In the case where heat treatment for reducingresistance is performed on the transparent conductive layer, the heattreatment can also serve as thermal treatment for improving the electriccharacteristics of a thin film transistor and the variation in theelectric characteristics of the same.

Next, a fifth photolithography step is performed to form a resist mask.Then, an unnecessary portion is removed by etching, so that a pixelelectrode layer 110 is formed.

In this fifth photolithography process, a storage capacitor is formedwith the capacitor wiring 108 and the pixel electrode layer 110, inwhich the gate insulating layer 102 and the oxide insulating layer 107in the capacitor portion are used as a dielectric.

In addition, in this fifth photolithography step, the first terminal 121and the second terminal 122 are covered with the resist mask, wherebytransparent conductive layers 128 and 129 are left in the terminalportions. The transparent conductive layers 128 and 129 each serve as anelectrode or a wiring that is used for connection with an FPC. Thetransparent conductive layer 128 formed over the first terminal 121 is aconnection terminal electrode which functions as an input terminal of agate wiring. The transparent conductive layer 129 formed over the secondterminal 122 is a connection terminal electrode which functions as aninput terminal of a source wiring.

Next, the resist mask is removed, and a cross-sectional diagram at thisstage is FIG. 7C. A plane view at this stage corresponds to FIG. 8.

FIGS. 9A1 and 9A2 are respectively a cross-sectional diagram and a plandiagram of a gate wiring terminal portion at this stage. FIG. 9A1 is across-sectional diagram along line E1-E2 of FIG. 9A2. In FIG. 9A1, atransparent conductive layer 155 formed over an oxide insulating layer154 is a connection terminal electrode which functions as an inputterminal. Furthermore, in a terminal portion of FIG. 9A1, a firstterminal 151 formed using the same material as the material of a gatewiring and a connection electrode layer 153 formed using the samematerial as the material of a source wiring overlap each other with agate insulating layer 152 interposed therebetween, and are electricallyconnected to each other through the transparent conductive layer 155.Note that a portion where the transparent conductive layer 128 and thefirst terminal 121 are in contact with each other, illustrated in FIG.7C corresponds to a portion where the transparent conductive layer 155and the first terminal 151 are in contact with each other in FIG. 9A1.

FIGS. 9B1 and 9B2 are a cross-sectional diagram and a plan view of asource wiring terminal portion which is different from those of the gatewiring terminal portion illustrated in FIG. 7C, respectively. Thecross-sectional diagram of FIG. 9B1 is taken along line F1-F2 of FIG.9B2. In FIG. 9B1, a transparent conductive layer 155 formed over anoxide insulating layer 154 is a connection terminal electrode whichfunctions as an input terminal. Further, in FIG. 9B1, in the terminalportion, an electrode layer 156 formed using the same material as thematerial of the gate wiring is located below and overlapped with asecond terminal 150 which is electrically connected to a source wiring,with a gate insulating layer 102 interposed therebetween. The electrodelayer 156 is not electrically connected to the second terminal 150, anda capacitor for preventing noise or static electricity can be formed ifthe potential of the electrode layer 156 is set to a potential differentfrom that of the second terminal 150, such as floating, GND, or 0 V. Thesecond terminal 150 is electrically connected to the transparentconductive layer 155 with the oxide insulating layer 154 therebetween.

A plurality of gate wirings, source wirings, and capacitor wirings areprovided depending on the pixel density. Further, in the terminalportion, the first terminal at the same potential as the gate wiring,the second terminal at the same potential as the source wiring, thethird terminal at the same potential as the capacitor wiring, and thelike are arranged. The number of each of the terminals to be providedmay be any number; the number of each terminal may be determined asappropriate.

Through these five photolithography steps, the storage capacitor and apixel thin film transistor portion including the thin film transistor170 of a bottom-gate staggered thin film transistor can be completedusing the five photomasks. By disposing the thin film transistor and thestorage capacitor in each pixel of a pixel portion in which pixels arearranged in matrix, one of substrates for manufacturing an active matrixdisplay device can be obtained. In this specification, such a substrateis referred to as an active matrix substrate for convenience.

In the case of manufacturing an active matrix liquid crystal displaydevice, an active matrix substrate and a counter substrate provided witha counter electrode are bonded to each other with a liquid crystal layerinterposed therebetween. Note that a common electrode electricallyconnected to the counter electrode on the counter substrate is providedover the active matrix substrate, and a fourth terminal electricallyconnected to the common electrode is provided in the terminal portion.The fourth terminal is provided so that the common electrode is set to afixed potential such as GND or 0 V.

Alternatively, a pixel electrode may be overlapped with a gate wiring ofa pixel adjacent to the pixel with an oxide insulating layer and a gateinsulating layer interposed therebetween, so that a storage capacitorwithout a capacitor wiring can be formed.

In an active matrix liquid crystal display device, pixel electrodesarranged in matrix are driven to display a display pattern on a screen.Specifically, voltage is applied between a selected pixel electrode anda counter electrode corresponding to the pixel electrode to performoptical modulation of a liquid crystal layer provided between the pixelelectrode and the counter electrode, so that this optical modulation isrecognized as a display pattern.

In displaying moving images, a liquid crystal display device has aproblem in that a long response time of liquid crystal molecules causesafterimages or blurring of moving images. In order to improve themoving-image characteristics of a liquid crystal display device, thereis a driving method called black insertion in which black is displayedon the whole screen every other frame period.

In addition, there is a driving method called double-frame rate drivingin which the vertical synchronizing frequency is increased to 1.5 timesor more, preferably twice or more to improve the moving-imagecharacteristics.

Further, in order to improve the moving-image characteristics of aliquid crystal display device, there is a driving method in which aplurality of LEDs (light-emitting diodes) or a plurality of EL lightsources are used to form a surface light source as a backlight, and eachlight source of the surface light source is independently driven toperform intermittent lighting in one frame period. As the surface lightsource, three or more kinds of LEDs may be used and/or an LED emittingwhite light may be used. Since a plurality of LEDs can be controlledindependently, the light emission timing of LEDs can be synchronizedwith the timing of optical modulation of a liquid crystal layer.According to this driving method, LEDs can be partly turned off;therefore, an effect of reducing power consumption can be obtainedparticularly in the case of displaying an image having a large part onwhich black is displayed.

By using any of these driving methods, the display characteristics of aliquid crystal display device, such as moving-image characteristics, canbe improved as compared to those of conventional liquid crystal displaydevices.

The n-channel transistor disclosed in this specification includes anoxide semiconductor layer which is used as a channel formation regionand has excellent dynamic characteristics; thus, it can be combined withany of these driving methods.

In manufacturing a light-emitting display device, one electrode (alsoreferred to as a cathode) of an organic light-emitting element is set toa low power supply potential such as GND or 0 V; thus, a terminalportion is provided with a fourth terminal for setting the cathode to alow power supply potential such as GND or 0 V. Also in manufacturing alight-emitting display device, a power supply line is provided inaddition to a source wiring and a gate wiring. Accordingly, the terminalportion is provided with a fifth terminal electrically connected to thepower supply line.

Further, in manufacturing a light-emitting display device, a partitionmay be provided using an organic resin layer between organiclight-emitting elements. In that case, the organic resin layer issubjected to heat treatment; therefore, the heat treatment can alsoserves as heat treatment for improving electric characteristics of athin film transistor and reducing variation in the electriccharacteristics of the same.

The use of an oxide semiconductor for a thin film transistor leads toreduction in manufacturing cost. In particular, the heat treatment fordehydration or dehydrogenation reduces impurities such as moisture andimprove the purity of the oxide semiconductor layer. Therefore, asemiconductor device which includes highly reliable thin filmtransistors having better electric characteristics can be providedwithout using a special sputtering apparatus in which the dew point inthe formation chamber is decreased or a high-purity oxide semiconductortarget.

By the heat treatment of the oxide semiconductor layer in the oxygenatmosphere, electric characteristics of the thin film transistor can bestabilized and increase in off current thereof can be prevented.Accordingly, a semiconductor device including a highly reliable thinfilm transistor having better electric characteristics can be provided.

Embodiment 3 can be implemented in appropriate combination with anyother embodiment described herein.

Embodiment 4

Described in Embodiment 4 is an example in which the manufacturingprocess is partly different from that in Embodiment 1. In Embodiment 4,an embodiment in which heat treatment for dehydration or dehydrogenationis performed after the formation of a source and drain electrode layers405 a and 405 b is illustrated in FIGS. 10A to 10D. In FIGS. 10A to 10D,the same reference numerals as the reference numerals in FIGS. 1A to 1Ddenote the same portions as the portions in FIGS. 1A to 1D.

Similarly to Embodiment 1, a gate electrode layer 401, a gate insulatinglayer 402, and an oxide semiconductor layer 430 are formed over asubstrate 400 having an insulating surface (see FIG. 10A).

A source and drain electrode layers 405 a and 405 b are formed over theoxide semiconductor layer 430, and part of the oxide semiconductor layer430 is etched, so that an oxide semiconductor layer 441 is formed (seeFIG. 10B).

Next, it is preferable that heat treatment and slowly cooling beperformed on the oxide semiconductor layer 441 and the source and drainelectrode layers 405 a and 405 b in an oxygen atmosphere. This heattreatment performs dehydration or dehydrogenation treatment on the oxidesemiconductor layer 441, so that an oxide semiconductor layer 403 isformed (see FIG. 10C). As a material of the source and drain electrodelayers 405 a and 405 b, it is preferable to use a material which hasheat resistance to this heat treatment, such as tungsten or molybdenum.

Next, an oxide insulating layer 407 is formed so as to be in contactwith the oxide semiconductor layer 403 by a sputtering method or a PCVDmethod without exposure to the air after the heat treatment. The oxideinsulating layer 407 is formed so as to be in contact with thedehydrated or dehydrogenated oxide semiconductor layer 403 by asputtering method or a PCVD method. In this manner, a thin filmtransistor 470 can be manufactured (see FIG. 10D).

It is preferable that after impurities such as H₂O, H, or OH included inthe oxide semiconductor layer are reduced by the above heat treatmentfor dehydration or dehydrogenation, slow cooling be performed. Afterthat, the formation of the oxide insulating layer so as be in contactwith the oxide semiconductor layer, and the like may be performed;accordingly, the reliability of the thin film transistor 470 can beimproved.

Further, after the oxide insulating layer 407 is formed, the thin filmtransistor 470 may be subjected to heat treatment (preferably at atemperature higher than or equal to 150° C. and lower than 350° C.) inan oxygen atmosphere or a nitrogen atmosphere. For example, heattreatment is performed at 250° C. for 1 hour in a nitrogen atmosphere.By the heat treatment, the oxide semiconductor layer 403 is heated whilebeing in contact with the oxide insulating layer 407; accordingly,variation in electric characteristics of the thin film transistor 470can be reduced.

Embodiment 4 can be combined with Embodiment 1 as appropriate.

Embodiment 5

A semiconductor device and a method for manufacturing the semiconductordevice will be described with reference to FIG. 11. Embodiment 1 can beapplied to the same portion(s), or a portion(s) or a step(s) having thesimilar function(s) as/to Embodiment 1, and the description thereof isnot repeated.

A thin film transistor 471 shown in FIG. 11 is an example in which aconductive layer 409 is provided so as to overlap a gate electrode layer401 and a channel region of an oxide semiconductor layer 403 with anoxide insulating layer 407 interposed therebetween.

FIG. 11 is a cross-sectional diagram of the thin film transistor 471included in a semiconductor device. The thin film transistor 471 is abottom-gate thin film transistor and includes, over a substrate 400which is a substrate having an insulating surface, the gate electrodelayer 401, a gate insulating layer 402, the oxide semiconductor layer403, a source and drain electrode layers 405 a and 405 b, the oxideinsulating layer 407, and the conductive layer 409. The conductive layer409 is provided over the oxide insulating layer 407 so as to overlap thegate electrode layer 401.

The conductive layer 409 can be formed using the same material and/ormethod as that/those of the gate electrode layer 401 or the source anddrain electrode layers 405 a and 405 b. In the case where a pixelelectrode layer is provided, the conductive layer 409 may be formedusing the same material and/or method as that/those of the pixelelectrode layer. In this embodiment, a stacked layer of a titaniumlayer, an aluminum layer, and a titanium layer is used as the conductivelayer 409.

The potential of the conductive layer 409 may be the same as ordifferent from that of the gate electrode layer 401, and the conductivelayer 409 can be serves as a gate electrode layer. The conductive layer409 may be in the floating state.

In addition, by providing the conductive layer 409 so as to overlap theoxide semiconductor layer 403, in a bias-temperature stress test(hereinafter, referred to as a BT test) for examining the reliability ofa thin film transistor, the threshold voltage of the thin filmtransistor 471 before and after the BT test can be controlled. Inparticular, the amount of change of the threshold voltage can be reducedin a −BT test under the following condition: the substrate temperatureis set to 150° C. and the voltage to be applied to the gate is set to−20 V.

Embodiment 5 can be combined with Embodiment 1 as appropriate.

Embodiment 6

A semiconductor device and a method for manufacturing the semiconductordevice will be described with reference to FIG. 12. Embodiment 1 can beapplied to the same portion(s), or a portion(s) or a step(s) having thesimilar function(s) as/to Embodiment 1, and the description thereof isnot repeated.

A thin film transistor 472 shown in FIG. 12 is an example in which aconductive layer 419 is provided so as to overlap a gate electrode layer401 and a channel region of an oxide semiconductor layer 403 with anoxide insulating layer 407 and an insulating layer 410 interposedtherebetween.

FIG. 12 is a cross-sectional diagram of the thin film transistor 472included in a semiconductor device. The thin film transistor 472 is abottom-gate thin film transistor and includes, over a substrate 400which is a substrate having an insulating surface, the gate electrodelayer 401, a gate insulating layer 402, the oxide semiconductor layer403, source and drain regions 404 a and 404 b, a source and drainelectrode layers 405 a and 405 b, the oxide insulating layer 407, theinsulating layer 410, and the conductive layer 419. The conductive layer409 is provided over the oxide insulating layer 407 and the insulatinglayer 410 so as to overlap the gate electrode layer 401.

In this embodiment, similarly to Embodiment 1, the oxide semiconductorlayer is formed over the gate insulating layer 402. The source and drainregions 404 a and 404 b are formed over the oxide semiconductor layer.It is preferable that before or after the formation of the source anddrain regions 404 a and 404 b, heat treatment is performed in an oxygenatmosphere and then slow cooling be performed in the/an oxygenatmosphere or an inert gas atmosphere.

In this embodiment, the source and drain regions 404 a and 404 b areeach formed using a Zn—O-based polycrystalline layer or a Zn-basedmicrocrystalline layer and are formed under a film formation conditionwhich is different from that of the oxide semiconductor layer 403 andeach have lower resistance. Further, in this embodiment, the source andthe drain regions 404 a and 404 b are in a polycrystalline state or amicrocrystalline state, and the oxide semiconductor layer 403 is also ina polycrystalline state or a microcrystalline state. The oxidesemiconductor layer 403 may be crystallized with heat treatment to be ina polycrystalline state or a microcrystalline state.

In this embodiment, the insulating layer 410 which serves as aplanarization layer is stacked over the oxide insulating layer 407, andan opening which reaches the source or drain electrode layer 405 b isformed in the oxide insulating layer 407 and the insulating layer 410. Aconductive layer is formed so as to cover the opening formed in theoxide insulating layer 407 and the insulating layer 410 and is etchedinto a predetermined shape, so that a conductive layer 419 and a pixelelectrode layer 411 are formed. In this manner, in the step for formingthe pixel electrode layer 411, the conductive layer 419 can be formedusing the same material and method as respective those of the pixelelectrode layer 411. In this embodiment, indium oxide-tin oxide alloycontaining silicon oxide (In—Sn—O-based oxide containing silicon oxide)is used to form the pixel electrode layer 411 and the conductive layer419.

The conductive layer 419 can be formed using the same material and/ormethod as that/those of the gate electrode layer 401 or the source anddrain electrode layers 405 a and 405 b.

The potential of the conductive layer 419 may be the same as ordifferent from that of the gate electrode layer 401. The conductivelayer 419 can be serves as a second gate electrode layer. The conductivelayer 419 may be in the floating state.

In addition, by providing the conductive layer 419 so as to overlap theoxide semiconductor layer 403, the threshold voltage of the thin filmtransistor can be controlled.

Embodiment 6 can be combined with Embodiment 1 as appropriate.

Embodiment 7

In Embodiment 7, an example of a channel-stop thin film transistor 1430will be described using FIGS. 13A to 13C. FIG. 13C is an example of atop view of a thin film transistor, cross-sectional view along dottedline Z1-Z2 of which corresponds to FIG. 13B. Described in Embodiment 7is an example in which gallium is not contained in an oxidesemiconductor layer of the thin film transistor 1430.

In FIG. 13A, a gate electrode layer 1401 is provided over a substrate1400. Next, a gate insulating layer 1402 is formed over the gateelectrode layer 1401, and an oxide semiconductor layer is formed overthe gate insulating layer 1402.

In this embodiment, the oxide semiconductor layer is formed using aSn—Zn—O-based oxide semiconductor by a sputtering method. Gallium is notused for the oxide semiconductor layer, so that an expensive target isnot used, which leads to cost reduction.

After the film deposition of the oxide semiconductor layer or after thepatterning of the oxide semiconductor layer, it is preferable that heattreatment be performed for dehydration or dehydrogenation in an oxygenatmosphere and then slow cooling be performed in the/an oxygenatmosphere or an inert gas atmosphere. As the heat treatment fordehydration or dehydrogenation, heat treatment at a temperature higherthan or equal to 200° C. and lower than the strain point of thesubstrate, preferably higher than or equal to 400° C. and lower than orequal to 700° C. is performed. The heat treatment in an oxygenatmosphere is performed on the oxide semiconductor layer, therebyforming an oxide semiconductor layer 1403 (see FIG. 13A). In thisembodiment, the oxide semiconductor layer 1403 is in a microcrystallinestate or in a polycrystalline state.

Next, a channel protection layer 1418 is provided on and in contact withthe oxide semiconductor layer 1403. The channel protection layer 1418can prevent damage (such as reduction in film thickness due to plasma oran etchant in etching) in a step of forming a source and drain regions1406 a and 1406 b performed later. Therefore, the reliability of thethin film transistor 1430 can be improved.

The channel protection layer 1418 may be formed successively after thedehydration or dehydrogenation without exposure to the air; in thatcase, each interface between stacked layers, which is not contaminatedby atmospheric components or impurity elements floating in the air, suchas moisture, hydrocarbon, or the like, can be obtained, so thatvariation in characteristics of the thin film transistor can be reduced.

The channel protection layer 1418 which is an oxide insulating layer isformed by a sputtering method, a PCVD method, or the like so as to be incontact with the dehydrated or dehydrogenated oxide semiconductor layer1403, so that the thin film transistor including the dehydrated ordehydrogenated oxide semiconductor layer 1403 as a channel formationregion can be manufactured.

The channel protection layer 1418 can be formed using an inorganicmaterial containing oxygen (e.g., silicon oxide, silicon oxynitride, orsilicon nitride oxide). As a manufacturing method thereof, a vapor phasegrowth method such as a plasma CVD method or a thermal CVD method, orsputtering can be used. The channel protection layer 1418 is subjectedto etching to be processed into a predetermined shape. In thisembodiment, the channel protection layer 1418 is formed in such a mannerthat a silicon oxide layer is formed by a sputtering method andprocessed by etching using a mask formed by photolithography.

Next, a source and drain regions 1406 a and 1406 b are formed over thechannel protection layer 1418 and the oxide semiconductor layer 1403. Inthis embodiment, the source and drain regions 1406 a and 1406 b areformed using a Zn—O-based microcrystalline layer or a Zn—O-basedpolycrystalline layer, which is formed under deposition conditionsdifferent from the deposition conditions of the oxide semiconductorlayer 1403, and are oxide semiconductor layers having lower resistance.Alternatively, the source and drain regions 1406 a and 1406 b may beformed using an Al—Zn—O-based non-single-crystal layer containingnitrogen, that is, an Al—Zn—O—N-based non-single-crystal layer (alsocalled an AZON layer).

Next, a source electrode layer 1405 a and a drain electrode layer 1405 bare formed over the source region 1406 a and the drain region 1406 b,respectively. In this manner, the thin film transistor 1430 ismanufactured (see FIG. 13B). The source electrode layer 1405 a and thedrain electrode layer 1405 b can be formed in a similar manner to themanner of the source region 1406 a and the drain region 1406 b.

By providing the source and drain regions 1406 a and 1406 b between theoxide semiconductor layer 1403 and the source and drain electrode layers1405 a and 1405 b, a good contact can be made between the oxidesemiconductor layer 1403 and the source and drain electrode layers 1405a and 1405 b, resulting in higher thermal stability than in Schottkyjunction. Moreover, the resistance of the source and drain regions 1406a and 1406 b is reduced, so that high mobility can be maintained evenwith a high drain voltage.

The source and drain regions 1406 a and 1406 b are not necessarilyprovided.

Further, after the channel protection layer 1418 is formed, the thinfilm transistor 1430 is subjected to heat treatment (preferably at atemperature higher than or equal to 150° C. and lower than 350° C.) inan oxygen atmosphere or an inert atmosphere. For example, heat treatmentis performed at 250° C. for 1 hour in a nitrogen atmosphere. By the heattreatment, the oxide semiconductor layer 1403 is heated while being incontact with the channel protection layer 1418; accordingly, variationin electric characteristics of the thin film transistor 1470 can bereduced. There is no particular limitation on this heat treatment(preferably at the temperature higher than or equal to 150° C. and lowerthan 350° C.) as long as it is performed after the formation of thechannel protection layer 1418. The heat treatment can be performedwithout increase in the number of steps by serving also heat treatmentin another step such as heat treatment in formation of a resin layer orheat treatment for reducing the resistance of a transparent conductivelayer.

Embodiment 7 can be implemented in appropriate combination with anyother embodiment described herein.

Embodiment 8

A semiconductor device and a method for manufacturing the semiconductordevice will be described with reference to FIGS. 14A and 14B. Embodiment7 can be applied to the same portion(s), or a portion(s) or a step(s)having the similar function(s) as/to Embodiment 7, and the descriptionthereof is not repeated.

A thin film transistor 1431 shown in FIG. 14A is an example in which aconductive layer 1419 is provided so as to overlap a gate electrodelayer 1401 and a channel region of an oxide semiconductor layer 1403with a channel protection layer 1418 and an insulating layer 1407interposed therebetween.

FIG. 14A is a cross-sectional diagram of the thin film transistor 1431included in a semiconductor device. The thin film transistor 1431 is abottom-gate thin film transistor and includes, over a substrate 1400which is a substrate having an insulating surface, the gate electrodelayer 1401, a gate insulating layer 1402, the oxide semiconductor layer1403, a source and drain regions 1406 a and 1406 b, a source and drainelectrode layers 1405 a and 1405 b, the insulating layer 1407, and theconductive layer 1419. The conductive layer 1409 is provided over theinsulating layer 1407 so as to overlap the gate electrode layer 401.

In this embodiment, similarly to Embodiment 1, the oxide semiconductorlayer is formed over the gate insulating layer 1402. The source anddrain regions 1406 a and 1406 b are formed over the oxide semiconductorlayer. It is preferable that before or after the formation of the sourceand drain regions 1406 a and 1406 b, heat treatment is performed in anoxygen atmosphere and then slow cooling be performed in the/an oxygenatmosphere or an inert gas atmosphere.

In this embodiment, the source and drain regions 1406 a and 1406 bformed over the oxide semiconductor layer 1403 are each formed using aZn—O-based microcrystalline layer or a Zn—O-based polycrystalline layerand are formed under a film formation condition which is different fromthat of the oxide semiconductor layer 1403 and each have lowerresistance. The oxide semiconductor layer 1403 is in an amorphous state.

The conductive layer 1409 can be formed using the same material and/ormethod as that/those of the gate electrode layer 1401 or the source anddrain electrode layers 1405 a and 1405 b. In the case where a pixelelectrode layer is provided, the conductive layer 1409 may be formedusing the same material and/or method as that/those of the pixelelectrode layer. In this embodiment, a stacked layer of a titaniumlayer, an aluminum layer, and a titanium layer is used as the conductivelayer 1409.

The potential of the conductive layer 1409 may be the same as ordifferent from that of the gate electrode layer 1401, and the conductivelayer 1409 can be serves as a gate electrode layer. The conductive layer1409 may be in the floating state.

In addition, by providing the conductive layer 1409 so as to overlap theoxide semiconductor layer 1403, in a bias-temperature stress test(hereinafter, referred to as a BT test) for examining the reliability ofa thin film transistor, the threshold voltage of the thin filmtransistor 1431 before and after the BT test can be controlled.

FIG. 14B illustrates an example which is partly different from FIG. 14A.The description of FIG. 14A can be applied to the same portion(s), or aportion(s) or a step(s) having the similar function(s) as/to FIG. 14A,and the description thereof is not repeated.

A thin film transistor 1432 shown in FIG. 14B is an example in which aconductive layer 1409 is provided so as to overlap a gate electrodelayer 1401 and a channel region of an oxide semiconductor layer 1403with a channel protection layer 1418 and an insulating layer 1408interposed therebetween.

In this embodiment, similarly to Embodiment 1, the oxide semiconductorlayer is formed over the gate insulating layer 1402. It is preferablethat before or after the formation of the oxide semiconductor layer,heat treatment for dehydration or dehydrogenation is performed in anoxygen atmosphere and then slow cooling be performed in the/an oxygenatmosphere or an inert gas atmosphere.

In FIG. 14B, the insulating layer 1408 is stacked over the insulatinglayer 1407 which serves as a planarization layer.

In FIG. 14B, a source and drain regions are not provided, and the oxidesemiconductor layer 1403 is directly in contact with the source anddrain electrode layers 1405 a and 1405 b.

Also in FIG. 14B, by providing the conductive layer 1409 so as tooverlap the oxide semiconductor layer 1403, in a BT test for examiningthe reliability of a thin film transistor, the threshold voltage of thethin film transistor 1431 before and after the BT test can becontrolled.

Embodiment 8 can be implemented in appropriate combination with anyother embodiment described herein.

Embodiment 9

In Embodiment 9, an example in which the structure is partly differentfrom that described in Embodiment 1 will be described with reference toFIG. 15. Embodiment 1 can be applied to the same portion(s), or aportion(s) or a step(s) having the similar function(s) as/to Embodiment1, and the description thereof is not repeated.

In this embodiment, it is preferable that heat treatment for dehydrationor dehydrogenation be performed in an oxygen atmosphere after a firstoxide semiconductor layer is patterned and then slow cooling beperformed in the/an oxygen atmosphere or an inert gas atmosphere. Theheat treatment performed on the first oxide semiconductor layer in theabove atmosphere can eliminate impurities such as hydrogen and moistureexisting in an oxide semiconductor layer 430.

Next, a second oxide semiconductor layer which serves as a source anddrain regions of a thin film transistor is formed over the first oxidesemiconductor layer, and then a conducive layer is formed.

Next, the first oxide semiconductor layer, the second oxidesemiconductor layer, and the conductive layer are etched in an etchingstep to form the oxide semiconductor layer 403, a source and drainregions 404 a and 404 b, and a source and drain electrode layers 405 aand 405 b. Note that only part of the oxide semiconductor layer 403 isetched, so that the oxide semiconductor layer 403 has a groove (adepressed portion).

Next, a silicon oxide layer is formed as an oxide insulating layer 407so as to be in contact with the oxide semiconductor layer 403 by asputtering method or a PCVD method. As the oxide insulating layer 407,which is formed to be in contact with the dehydrated or dehydrogenatedoxide semiconductor layer, is formed using an inorganic insulating layerwhich includes moisture, a hydrogen ion, OH⁻, and the like as less aspossible and blocks entry of them from the outside; specifically, asilicon oxide layer or a silicon nitride oxide layer is used. A siliconnitride layer maybe stacked on the oxide insulating layer.

The oxide insulating layer 407 is formed by a sputtering method, a PCVDmethod, or the like so as to be in contact with the dehydrated ordehydrogenated oxide semiconductor layer 1403, so that a thin filmtransistor 473 including the dehydrated or dehydrogenated oxidesemiconductor layer 403 as a channel formation region can bemanufactured (see FIG. 15).

In this structure shown in FIG. 15, the source and drain regions 404 aand 404 b are formed using any of the following; an In—Ga—Zn—O-basednon-single-crystal layer; an Al—Zn—O-based non-single-crystal layer; oran Al—Zn—O-based non-single-crystal layer containing nitrogen, that is,an Al—Zn—O—N-based non-single-crystal layer.

The source region is provided between the oxide semiconductor layer 403and the source electrode layer and the drain region is provided betweenthe oxide semiconductor layer 403 and the drain electrode layer.

It is preferable that the second oxide semiconductor layer used as thesource and drain regions 404 and 404 b of the thin film transistor 473be preferably thinner than the first oxide semiconductor layer used asthe first oxide semiconductor layer used as a channel formation regionand have higher conductivity (electrical conductivity) than the firstoxide semiconductor layer.

Further, the first oxide semiconductor layer used as the channelformation region may have an amorphous structure and the second oxidesemiconductor layer used as the source and drain regions may include acrystal grain (nanocrystal) in an amorphous structure. The crystal grain(nanocrystal) in the second oxide semiconductor layer used as the sourceand drain regions has a diameter of 1 nm to 10 nm, typically about 2 nmto 4 nm.

Further, after the oxide insulating layer 407 is formed, the thin filmtransistor 473 may be subjected to heat treatment (preferably at atemperature higher than or equal to 150° C. and lower than 350° C.) inan oxygen atmosphere or a nitrogen atmosphere. For example, heattreatment is performed at 250° C. for 1 hour in a nitrogen atmosphere.By the heat treatment, the oxide semiconductor layer 403 is heated whilebeing in contact with the oxide insulating layer 407; accordingly,variation in electric characteristics of the thin film transistor 473can be reduced.

Embodiment 9 can be implemented in appropriate combination with anyother embodiment described herein.

Embodiment 10

In Embodiment 10, an example will be described in which at least a partof a driver circuit and a thin film transistor disposed in a pixelportion are formed over one substrate.

The thin film transistor disposed in the pixel portion is formed inaccordance with any of Embodiments 1 to 9. Further, the thin filmtransistor described in any of Embodiments 1 to 9 is an n-channel TFT,and thus part of a driver circuit that can include an n-channel TFTamong driver circuits is formed over the same substrate as that of thethin film transistor in the pixel portion.

FIG. 16A illustrates an example of a block diagram of an active matrixdisplay device. Over a substrate 5300 of the display device, a pixelportion 5301, a first scan line driver circuit 5302, a second scan linedriver circuit 5303, and a signal line driver circuit 5304 are provided.In the pixel portion 5301, a plurality of signal lines are provided bybeing extended from the signal line driver circuit 5304, and a pluralityof scan lines are provided by being extended from the first scan linedriver circuit 5302 and the second scan line driver circuit 5303. Pixelseach including a display element are arranged in matrix at intersectionsof the scan lines and the signal lines. The substrate 5300 of thedisplay device is connected to a timing control circuit 5305 (alsocalled a controller or a control IC) with a connection portion such as aflexible printed circuit (FPC).

In FIG. 16A, the first scan line driver circuit 5302, the second scanline driver circuit 5303, and the signal line driver circuit 5304 areformed over the same substrate 5300 as the pixel portion 5301.Therefore, the number of components of a driver circuit and the likewhich are provided externally is decreased, which leads to costreduction. Further, the number of wirings in the connection portion dueto extension of wirings is decreased as compared to the case where adriver circuit is provided for the outside of the substrate 5300, whichleads to improvement of the reliability or improvement of the yield.

As an example, the timing control circuit 5305 supplies a first scanline driver circuit start signal (GSP1) and a first scan line drivercircuit clock signal (GCLK1) to the first scan line driver circuit 5302.Further, as an example, the timing control circuit 5305 supplies asecond scan line driver circuit start signal (GSP2) (also called a startpulse) and a second scan line driver circuit clock signal (GCLK2) to thesecond scan line driver circuit 5303. Further, as an example, the timingcontrol circuit 5305 supplies a signal line driver circuit start signal(SSP), a signal line driver circuit clock signal (SCLK), video signaldata (DATA) (also simply called a video signal) and a latch signal (LAT)to the signal line driver circuit 5304. The clock signals may be aplurality of clock signals whose periods are deviated from each other ormay be supplied together with an inverted clock signal (CKB). One of thefirst scan line driver circuit 5302 and the second scan line drivercircuit 5303 can be omitted.

FIG. 16B shows a structure in which circuits with low driving frequency(e.g., the first scan line driver circuit 5302 and the second scan linedriver circuit 5303) are formed over the same substrate 5300 as thepixel portion 5301 and the signal line driver circuit 5304 is formedover a substrate which is different from that of the pixel portion 5301.With this structure, a driver circuit formed over the substrate 5300 canbe formed using a thin film transistor with lower field-effect mobilityas compared to that of a transistor formed using a single crystalsemiconductor. Accordingly, increase in the size of the display device,reduction in the number of steps, reduction in cost, improvement inyield, or the like can be achieved.

The thin film transistor described in any of Embodiments 1 to 9 is ann-channel TFT. In FIGS. 17A and 17B, an example of a structure andoperation of a signal line driver circuit which is formed using ann-channel TFT is described.

The signal line driver circuit includes a shift register 5601 and aswitching circuit 5602. The switching circuit 5602 includes a pluralityof switching circuits 5602 _(—1) to 5602_N (N is a natural number). Theswitching circuits 5602_1 to 5602_N each include a plurality of thinfilm transistors 5603_1 to 5603 _(—) k (k is a natural number). Anexample in which the thin film transistors 5603_1 to 5603 _(—) k aren-channel TFTs will be described.

A connection relation of the signal line driver circuit will bedescribed by using the switching circuit 5602_1 as an example. Firstterminals of the thin film transistors 5603_1 to 5603 _(—) k areconnected to respective wirings 5604_1 to 5604 _(—) k. Second terminalsof the thin film transistors 5603_1 to 5603 _(—) k are connected torespective signal lines S1 to Sk. Gates of the thin film transistors5603_1 to 5603 _(—) k are connected to a wiring 5605_1.

The shift register 5601 has a function of outputting an H level signal(also called an H signal or a high power supply potential level) to thewirings 5605_1 to 5605_N in order so as to select the switching circuits5602_1 to 5602_N in order.

The switching circuit 5602_1 has a function of controlling electricalcontinuity between the wirings 5604_1 to 5604 _(—) k and the signallines S1 to Sk (electrical continuity between the first terminal and thesecond terminal), namely a function of controlling whether or not tosupply potentials of the wirings 5604_1 to 5604 _(—) k to the signallines S1 to Sk. In this manner, the switching circuit 5602_1 functionsas a selector. Further, the thin film transistors 5603_1 to 5603 _(—) keach have a function of controlling electrical continuity between theirrespective wirings 5604_1 to 5604 _(—) k and their respective signallines S1 to Sk, namely a function of controlling whether or not tosupply their respective potentials of the wirings 5604_1 to 5604 _(—) kto their respective signal lines S1 to Sk. In this manner, each of thethin film transistors 5603_1 to 5603 _(—) k functions as a switch.

Note that video signal data (DATA) is input to each of the wirings5604_1 to 5604 _(—) k. The video signal data (DATA) is an analog signalcorresponding to image data or an image signal in many cases.

Next, operation of the signal line driver circuit in FIG. 17A will bedescribed with reference to a timing chart in FIG. 17B. In FIG. 17B, anexample of signals Sout_1 to Sout_N and signals Vdata_1 to Vdata_(—) kis shown. The signals Sout_1 to Sout_N are examples of output signals ofthe shift register 5601 and the signals Vdata_1 to Vdata_(—) k areexamples of respective signals which are input to the wirings 5604_1 to5604 _(—) k. One operation period of the signal line driver circuitcorresponds to one gate selection period in a display device. Forexample, one gate selection period is divided into periods T1 to TN. Theperiods T1 to TN are periods for writing video signal data (DATA) topixels in selected rows.

Note that as for the components shown in the drawings in Embodiment 10,distortion in a signal waveform and the like are exaggerated to be shownfor clarity, in some cases. Therefore, there is no limitation on thescale of the components.

In the periods T1 to TN, the shift register 5601 sequentially outputs anH level signal to the wirings 5605_1 to 5605_N. For example, in theperiod T1, the shift register 5601 outputs an H level signal to thewiring 5605_1. Consequently, the thin film transistors 5603_1 to 5603_(—) k are turned on, which brings electrical continuity between thewirings 5604_1 to 5604 _(—) k and the signal lines S1 to Sk. At thattime, Data (S1) to Data (Sk) are input to the wirings 5604_1 to 5604_(—) k, respectively. The Data (S1) to Data (Sk) are written into pixelsin a selected row in the first to k-th columns through their respectivethin film transistors 5603_1 to 5603 _(—) k. Thus, in the periods T1 toTN, video signal data (DATA) is written into the pixels in the selectedrow sequentially every k columns.

By writing video signal data (DATA) to pixels per a plurality of columnsas described above, the number of video signal data (DATA) or the numberof wirings can be reduced. Thus, the number of connections to anexternal circuit can be reduced. Further, by writing video signals topixels per a plurality of columns, writing time of period can beextended and insufficiency of writing of video signals can be prevented.

Note that as the shift register 5601 and the switching circuit 5602, acircuit including the thin film transistor described in any ofEmbodiments 1 to 9 can be used. In that case, all the transistorsincluded in the shift transistor 5601 can be n-channel transistors orall the transistors included in the shift transistor 5601 can bep-channel transistors.

An embodiment of a shift register which is used for part(s) of a scanline driver circuit and/or a signal line driver circuit will bedescribed with reference to FIGS. 18A to 18C and FIGS. 19A and 19B.

The scan line driver circuit includes a shift register. The scan linedriver circuit may also include a level shifter, a buffer, or the likein some cases. In the scan line driver circuit, when the clock signal(CLK) and the start pulse signal (SP) are input to the shift register, aselection signal is generated. The generated selection signal isbuffered and amplified by the buffer, and then supplied to acorresponding scan line. Gate electrodes of transistors in pixels of oneline are connected to the scan line. In order to turn on the transistorsin the pixels of one line all at once, a buffer which can supply a largecurrent is used.

The shift register includes first to N-th pulse output circuits 10_1 to10_N (N is a natural number of 3 or more) (see FIG. 18A). A first clocksignal CK1 from a first wiring 11, a second clock signal CK2 from asecond wiring 12, a third clock signal CK3 from a third wiring 13, and afourth clock signal CK4 from a fourth wiring 14 are supplied to thefirst to N-th pulse output circuits 10_1 to 10_N of the shift registershown in FIG. 18A. A start pulse SP1 (a first start pulse) from a fifthwiring 15 is input to the first pulse output circuit 10_1. A signal fromthe pulse output circuit in the previous stage (the signal called aprevious stage signal OUT (n−1)) (n is a natural number of more than orequal to 2 and lower than or equal to N) is input to the n-th pulseoutput circuit in the second or later stage. A signal from the thirdpulse output circuit 10_3 in the stage two stages after the first pulseoutput circuit 10_1 is input to the first pulse output circuit 10_1;that is, a signal from the (n+2)-th pulse output circuit 10_(n+2) in thestage two stages after the n-th pulse output circuit 10 _(—) n (thesignal called a next stage signal OUT (n+2)) is input to the n-th pulseoutput circuit. A first output signal (corresponding one of OUT (1) (SR)to OUT (N) (SR)) to be input to the pulse output circuit of the previousand/or the next stage and a second output signal (corresponding one ofOUT (1) to OUT (N)) which is electrically connected to another wiring orthe like are output from each of the pulse output circuits. Note that asshown in FIG. 18A, the next stage signal OUT (n+2) is not input to thelast two stages of the shift register; therefore, as an example, asecond start pulse SP2 may be input to one of the last two stages of theshift register and a third start pulse SP3 may be input to the other ofthe same.

Note that a clock signal (CK) is a signal which oscillates between an Hlevel and an L level (also called an L signal or a low power supplypotential level) at a constant cycle. The first to the fourth clocksignals (CK1) to (CK4) are delayed by ¼ period sequentially. In thisembodiment, by using the first to fourth clock signals (CK1) to (CK4),control of driving of the pulse output circuit or the like is performed.Note that the clock signal is also called GCK or SCK depending on adriver circuit to which the clock signal is input; however, descriptionis made here using CK as the clock signal.

Each of the first to N-th pulse output circuits 10_1 to 10_N includes afirst input terminal 21, a second input terminal 22, a third inputterminal 23, a fourth input terminal 24, a fifth input terminal 25, afirst output terminal 26, and a second output terminal 27 (see FIG.18B). The first input terminal 21, the second input terminal 22, and thethird input terminal 23 are electrically connected to any of the firstto fourth wirings 11 to 14. For example, in FIG. 18A, the first inputterminal 21 of the first pulse output circuit 10_1 is electricallyconnected to the first wiring 11, the second input terminal 22 of thefirst pulse output circuit 10_1 is electrically connected to the secondwiring 12, and the third input terminal 23 of the first pulse outputcircuit 10_1 is electrically connected to the third wiring 13. Inaddition, the first input terminal 21 of the second pulse output circuit102 is electrically connected to the second wiring 12, the second inputterminal 22 of the second pulse output circuit 102 is electricallyconnected to the third wiring 13, and the third input terminal 23 of thesecond pulse output circuit 10_2 is electrically connected to the fourthwiring 14.

In the first pulse output circuit 10_1, the first clock signal CK1 isinput to the first input terminal 21; the second clock signal CK2 isinput to the second input terminal 22; the third clock signal CK3 isinput to the third input terminal 23; the first start pulse SP1 is inputto the fourth input terminal 24; the next stage signal OUT (3) is inputto the fifth input terminal 25; the first output signal OUT (1) (SR) isoutput from the first output terminal 26; and the second output signalOUT (1) is output from the second output terminal 27.

In each of the first to N-th pulse output circuits 10_1 to 10_N, as wellas a thin film transistor (TFT) having three terminals, the thin filmtransistor having four terminals described in the above embodiment canbe used. In this specification, in the case where two gate electrodesare provided with a semiconductor layer interposed therebetween in athin film transistor, one gate electrode under the semiconductor layercan also be referred to as a lower gate electrode and the other gateelectrode over the semiconductor layer can also be referred to as anupper gate electrode.

In the case where an oxide semiconductor is used for a semiconductorlayer including a channel formation region of a thin film transistor,the threshold voltage may be shifted in a negative or positive directiondepending on a manufacturing process thereof. Thus, it is preferablethat the thin film transistor in which an oxide semiconductor is usedfor a semiconductor layer including a channel formation region have astructure where the threshold voltage can be controlled. The thresholdvoltage of the thin film transistor having four terminals can becontrolled to be a predetermined value by controlling the potential(s)of the lower gate electrode and/or the upper gate electrode.

Next, an example of a specific circuit structure of the pulse outputcircuit which is shown in FIG. 18B will be described with reference toFIG. 18C.

The pulse output circuit which is shown in FIG. 18C includes first tothirteenth transistors 31 to 43. Signals or power supply potentials aresupplied to the first to thirteenth transistors 31 to 43 from a powersupply line 51 to which a first power supply potential VDD is supplied,a power supply line 52 to which a second power supply potential VCC issupplied, and a power supply line 53 to which a third power supplypotential VSS is supplied. Here, a magnitude relation of the powersupply potential of each power supply line in FIG. 18C is as follows:the first power supply potential VDD is higher than or equal to thesecond power supply potential VCC and the second power supply potentialVCC is higher than the third power supply potential VSS. Although thefirst to fourth clock signals (CK1) to (CK4) are signals each of whichalternates between an H level signal and an L level signal at a constantcycle; and the potential is VDD when the clock signal is at the H level,and the potential is VSS when the clock signal is at the L level. Thepotential VDD of the power supply line 51 is set to be higher than thepotential VCC of the power supply line 52, thereby reducing thepotential applied to the gate electrode of the transistor withoutadversely effecting the operation; thus, the shift of the thresholdvalue of the transistor can be reduced and deterioration can besuppressed. It is preferable that thin film transistors each having fourterminals be used as the first transistor 31 and the sixth to ninthtransistors 36 to 39 among the first transistor 31 to the thirteenthtransistor 43. The first transistor 31 and the sixth to ninthtransistors 36 to 39 are transistors by which the potential of a nodeconnected to one electrode of a source and drain electrodes needs to bechanged by a control signal to a gate electrode, and increase in theresponse speed to the control signal input to the gate electrode of eachof them (steep rising of the on-current) can reduce malfunction of thepulse output circuit. Therefore, by using thin film transistors eachhaving four terminals, the threshold voltage can be controlled, so thatthe malfunction of the pulse output circuit can be reduced.

In FIG. 18C, a first terminal of the first transistor 31 is electricallyconnected to the power supply line 51, a second terminal of the firsttransistor 31 is electrically connected to a first terminal of the ninthtransistor 39, and a gate electrode (a lower gate electrode and an uppergate electrode) of the first transistor 31 is electrically connected toa fourth input terminal 24. A first terminal of the second transistor 32is electrically connected to the power supply line 53, a second terminalof the second transistor 32 is electrically connected to the firstterminal of the ninth transistor 39, and a gate electrode of the secondtransistor 32 is electrically connected to a gate electrode of thefourth transistor 34. A first terminal of the third transistor 33 iselectrically connected to the first input terminal 21, and a secondterminal of the third transistor 33 is electrically connected to thefirst output terminal 26. A first terminal of the fourth transistor 34is electrically connected to the power supply line 53, and a secondterminal of the fourth transistor 34 is electrically connected to thefirst output terminal 26. A first terminal of the fifth transistor 35 iselectrically connected to the power supply line 53, a second terminal ofthe fifth transistor 35 is electrically connected to the gate electrodeof the second transistor 32 and the gate electrode of the fourthtransistor 34, and a gate electrode of the fifth transistor 35 iselectrically connected to the fourth input terminal 24. A first terminalof the sixth transistor 36 is electrically connected to the power supplyline 52, a second terminal of the sixth transistor 36 is electricallyconnected to the gate electrode of the second transistor 32 and the gateelectrode of the fourth transistor 34, and a gate electrode (a lowergate electrode and an upper gate electrode) of the sixth transistor 36is electrically connected to the fifth input terminal 25. A firstterminal of the seventh transistor 37 is electrically connected to thepower supply line 52, a second terminal of the seventh transistor 37 iselectrically connected to a second terminal of the eighth transistor 38,and a gate electrode (a lower gate electrode and an upper gateelectrode) of the seventh transistor 37 is electrically connected to thethird input terminal 23. A first terminal of the eighth transistor 38 iselectrically connected to the gate electrode of the second transistor 32and the gate electrode of the fourth transistor 34, and a gate electrode(a lower gate electrode and an upper gate electrode) of the eighthtransistor 38 is electrically connected to the second input terminal 22.The first terminal of the ninth transistor 39 is electrically connectedto the second terminal of the first transistor 31 and the secondterminal of the second transistor 32, a second terminal of the ninthtransistor 39 is electrically connected to the gate electrode of thethird transistor 33 and the gate electrode of the tenth transistor 40,and a gate electrode (a lower gate electrode and an upper gateelectrode) of the ninth transistor 39 is electrically connected to thepower supply line 52. A first terminal of the tenth transistor 40 iselectrically connected to the first input terminal 21, a second terminalof the tenth transistor 40 is electrically connected to the secondoutput terminal 27, and a gate electrode of the tenth transistor 40 iselectrically connected to the second terminal of the ninth transistor39. A first terminal of the eleventh transistor 41 is electricallyconnected to the power supply line 53, a second terminal of the eleventhtransistor 41 is electrically connected to the second output terminal27, and a gate electrode of the eleventh transistor 41 is electricallyconnected to the gate electrode of the second transistor 32 and the gateelectrode of the fourth transistor 34. A first terminal of the twelfthtransistor 42 is electrically connected to the power supply line 53, asecond terminal of the twelfth transistor 42 is electrically connectedto the second output terminal 27, and a gate electrode of the twelfthtransistor 42 is electrically connected to the gate electrode (the lowergate electrode and the upper gate electrode) of the seventh transistor37. A first terminal of the thirteenth transistor 43 is electricallyconnected to the power supply line 53, a second terminal of thethirteenth transistor 43 is electrically connected to the first outputterminal 26, and a gate electrode of the thirteenth transistor 43 iselectrically connected to the gate electrode (the lower gate electrodeand the upper gate electrode) of the seventh transistor 37.

In FIG. 18C, a connection point of the gate electrode of the thirdtransistor 33, the gate electrode of the tenth transistor 40, and thesecond terminal of the ninth transistor 39 is referred to as a node A.In addition, a connection point of the gate electrode of the secondtransistor 32, the gate electrode of the fourth transistor 34, thesecond terminal of the fifth transistor 35, the second terminal of thesixth transistor 36, the first terminal of the eighth transistor 38, andthe gate electrode of the eleventh transistor 41 is referred to as anode B.

In FIG. 19A, signals which are input or output to/from the first inputterminal 21 to the fifth input terminal 25, the first output terminal26, and the second output terminal 27 when the pulse output circuitdescribed with reference to FIG. 18C is applied to the first pulseoutput circuit 10_1 are shown.

Specifically, the first clock signal CK1 is input to the first inputterminal 21; the second clock signal CK2 is input to the second inputterminal 22; the third clock signal CK3 is input to the third inputterminal 23; the start pulse is input to the fourth input terminal 24;the next stage signal OUT (3) is input to the fifth input terminal 25;the first output signal OUT (1) (SR) is output from the first outputterminal 26; and the second output signal OUT (1) is output from thesecond output terminal 27.

Note that a thin film transistor is an element having at least threeterminals of a gate, a drain, and a source. The thin film transistor hasa semiconductor in which a channel region is formed in a regionoverlapped with the gate, and current which flows between the drain andthe source through the channel region can be controlled by controllingthe potential of the gate. Here, since the source and the drain of thethin film transistor may interchange depending on the structure, theoperating condition, and the like of the thin film transistor, it isdifficult to define which is a source or a drain. Therefore, regionsfunctioning as a source and a drain are not called a source and a drainin some cases; in that case, for example, one of the source and thedrain may be referred to as a first terminal and the other thereof maybe referred to as a second terminal.

In FIGS. 18C and 19A, a capacitor may be provided for performing abootstrap operation with the node A in the floating state. Further, inorder to keep the potential of the node B, a capacitor one electrode ofwhich is electrically connected to the node B may be provided.

FIG. 19B shows a timing chart of a shift register including theplurality of pulse output circuits shown in FIG. 19A. In the case wherethe shift register is a scan line driver circuit, a period 61 in FIG.19B is a vertical retrace period and a period 62 is a gate selectionperiod.

As shown in FIG. 19A, the ninth transistor 39 whose gate is suppliedwith the second power supply potential VCC offers advantages describedbelow before and after a bootstrap operation.

In the case where the ninth transistor 39 whose gate electrode issupplied with the second power supply potential VCC, as the potential ofthe node A is increased by the bootstrap operation, the potential of asource which is the second terminal of the first transistor 31 increasesto a level higher than the first power supply potential VDD. Then, thefirst terminal of the first transistor 31, namely the power supply line51, comes to serve as the source thereof. Therefore, in the firsttransistor 31, a large bias voltage is applied and thus significantstress is applied between the gate and the source and between the gateand the drain, which may cause deterioration of the transistor. Theninth transistor 39 whose gate electrode is supplied with the secondpower supply potential VCC can prevent the increase of the potential ofthe second terminal of the first transistor 31 while the potential ofthe node A is increased by the bootstrap operation. In other words, byproviding the ninth transistor 39, a negative bias voltage appliedbetween the gate and the source of the first transistor 31 can bereduced. Accordingly, with the circuit structure according to thisembodiment, the negative bias voltage applied between the gate and thesource of the first transistor 31 can be reduced, so that deteriorationof the first transistor 31 due to stress can be suppressed.

The ninth transistor 39 may be provided so as to be connected betweenthe second terminal of the first transistor 31 and the gate of the thirdtransistor 33 through the first terminal and the second terminalthereof. In the case where a shift register including the plurality ofpulse output circuits shown in this embodiment is used in a signal linedriver circuit having more stages than a scan line driver circuit, theninth transistor 39 may be omitted and the number of transistors can bereduced.

When an oxide semiconductor is used for semiconductor layers of thefirst transistor 31 to the thirteenth transistor 43, off-current of eachthin film transistor can be reduced, on-current and field effectmobility can be increased, and the degree of deterioration can beincreased; accordingly, malfunction in a circuit can be reduced. Thedegree of deterioration of the transistor formed using an oxidesemiconductor, which is caused by application of a high potential to thegate electrode, is small in comparison with that of the transistorformed using amorphous silicon. Therefore, even when the first powersupply potential VDD is supplied to a power supply line to which thesecond power supply potential VCC is supplied, a similar operation canbe performed, and the number of power supply lines which are lead in thecircuit can be reduced, so that the circuit can be miniaturized.

Even when a wiring connection is changed so that the clock signal whichis supplied to the gate electrode (the lower gate electrode and theupper gate electrode) of the seventh transistor 37 through the thirdinput terminal 23 and the clock signal which is supplied to the gateelectrode (the lower gate electrode and the upper gate electrode) of theeighth transistor 38 through the second input terminal 22 are the clocksignal which is supplied to the gate electrode (the lower gate electrodeand the upper gate electrode) of the seventh transistor 37 through thesecond input terminal 22 and the clock signal which is supplied to thegate electrode (the lower gate electrode and the upper gate electrode)of the eighth transistor 38 through the third input terminal 23,respectively, a similar operation effect can be obtained. Note that inthe shift register shown in FIG. 19A, In the case where after theseventh transistor 37 and the eighth transistor 38 are both on, theseventh transistor 37 is turned off and the eighth transistor 38 is keptto be on, and then the seventh transistor 37 is kept to be off and theeighth transistor 38 is turned off, a decrease in the potential of thenode B, which is caused by a decrease in the potentials of the secondinput terminal 22 and the third input terminal 23, occurs twice becauseof a decrease in the potential of the gate electrode of the seventhtransistor 37 and a decrease in the potential of the gate electrode ofthe eighth transistor 38. On the other hand, in the shift register shownin FIG. 19A, as shown in the FIG. 18B, in the case where after theseventh transistor 37 and the eighth transistor 38 are both on, theseventh transistor 37 is kept to be on and the eighth transistor 38 isturned off, and then the seventh transistor 37 is turned off and theeighth transistor 38 is kept to be off, the frequency of decrease in thepotential of the node B, which is caused by the decreases in thepotentials of the second input terminal 22 and the third input terminal23, can be reduced to one which occurs when the potential of the gateelectrode of the eighth transistor 38 is decreased. Therefore, with useof the clock signal which is supplied to the gate electrode (the lowergate electrode and the upper gate electrode) of the seventh transistor37 through the third input terminal 23 and the clock signal which issupplied to the gate electrode (the lower gate electrode and the uppergate electrode) of the eighth transistor 38 through the second inputterminal 22, variation in the potential of the node B is reduced; thus,noise can be reduced, which is preferable.

In this manner, in a period during which the potentials of the firstoutput terminal 26 and the second output terminal 27 are kept at the Llevel, an H level signal is regularly supplied to the node B;accordingly, malfunction of a pulse output circuit can be suppressed.

Embodiment 10 can be implemented in appropriate combination with anyother embodiment described herein.

Embodiment 11

A thin film transistor is manufactured and used for a pixel portion andfurther for a driver circuit, so that a semiconductor device having adisplay function (also referred to as a display device) can bemanufactured. Furthermore, part or whole of a driver circuit using athin film transistor can be formed over the same substrate as thesubstrate of a pixel portion, so that a system-on-panel can be obtained.

The display device includes a display element. As the display element, aliquid crystal element (also referred to as a liquid crystal displayelement) or a light-emitting element (also referred to as alight-emitting display element) can be used. Light-emitting elementsinclude, in its category, an element whose luminance is controlled bycurrent or voltage, and specifically include an inorganicelectroluminescent (EL) element, an organic EL element, and the like.Furthermore, a display medium whose contrast is changed by an electriceffect, such as electronic ink, can be used.

In addition, the display device includes a panel in which the displayelement is sealed, and a module in which an IC or the like including acontroller is mounted on the panel. The display device also relates toan element substrate, which corresponds to one mode before the displayelement is completed in a manufacturing process of the display device,and the element substrate is provided with means for supplying currentto the display element in each of a plurality of pixels. Specifically,the element substrate may be in a state after only a pixel electrode(also referred to as a pixel electrode layer) of the display element isformed, a state in the period after a conductive layer to be a pixelelectrode is formed and before the conductive layer is etched to formthe pixel electrode, or any of other states.

Note that a display device in this specification means an image displaydevice, a display device, or a light source (including a lightingdevice). Furthermore, the display device also includes the followingmodules in its category: a module to which a connector such as aflexible printed circuit (FPC), a tape automated bonding (TAB) tape, ora tape carrier package (TCP) is attached; a module having a TAB tape ora TCP at the tip of which a printed wiring board is provided; and amodule in which an integrated circuit (IC) is directly mounted on adisplay element by a chip on glass (COG) method.

The appearance and a cross section of a liquid crystal display panel,which is an embodiment of a semiconductor device, will be described withreference to FIGS. 20A1, 20A2 and 20B. FIGS. 20A1 and 20A2 are each aplan view of a panel in which highly reliable thin film transistors 4010and 4011 each including an oxide semiconductor layer formed over a firstsubstrate 4001 which is described in Embodiment 3 and a liquid crystalelement 4013 are sealed between the first substrate 4001 and a secondsubstrate 4006 with a sealant 4005. FIG. 20B is a cross-sectionaldiagram taken along line M-N of FIGS. 20A1 and 20A2.

The sealant 4005 is provided to surround a pixel portion 4002 and a scanline driver circuit 4004 that are provided over the first substrate4001. The second substrate 4006 is provided over the pixel portion 4002and the scan line driver circuit 4004. Therefore, the pixel portion 4002and the scan line driver circuit 4004 are sealed together with a liquidcrystal layer 4008, by the first substrate 4001, the sealant 4005, andthe second substrate 4006. A signal line driver circuit 4003 that isformed using a single crystal semiconductor layer or a polycrystallinesemiconductor layer over a substrate separately prepared is mounted in aregion different from the region surrounded by the sealant 4005 over thefirst substrate 4001.

Note that there is no particular limitation on the connection method ofa driver circuit which is separately formed, and a COG method, a wirebonding method, a TAB method, or the like can be used. FIG. 20A1illustrates an example of mounting the signal line driver circuit 4003by a COG method, and FIG. 20A2 illustrates an example of mounting thesignal line driver circuit 4003 by a TAB method.

The pixel portion 4002 and the scan line driver circuit 4004 providedover the first substrate 4001 each include a plurality of thin filmtransistors. FIG. 20B illustrates the thin film transistor 4010 includedin the pixel portion 4002 and the thin film transistor 4011 included inthe scan line driver circuit 4004. Protection insulating layers 4020 and4021 are provided over the thin film transistors 4010 and 4011.

As the thin film transistors 4010 and 4011, the thin film transistorincluding an oxide semiconductor layer which is described in Embodiment3 can be employed. Alternatively, the thin film transistor described inEmbodiment 1 or Embodiment 2 may be employed. In this embodiment, thethin film transistors 4010 and 4011 are n-channel thin film transistors.

A pixel electrode layer 4030 included in the liquid crystal element 4013is electrically connected to the thin film transistor 4010. A counterelectrode layer 4031 of the liquid crystal element 4013 is formed on thesecond substrate 4006. A portion where the pixel electrode layer 4030,the counter electrode layer 4031, and the liquid crystal layer 4008overlap one another corresponds to the liquid crystal element 4013. Notethat the pixel electrode layer 4030 and the counter electrode layer 4031are provided with an insulating layer 4032 and an insulating layer 4033respectively, the insulating layer 4032 and the insulating layer 4033each function as an alignment film. The liquid crystal layer 4008 issandwiched between the pixel electrode layer 4030 and the counterelectrode layer 4031 with the insulating layers 4032 and 4033 interposedtherebetween.

Note that the first substrate 4001 and the second substrate 4006 can bemade of glass, metal (typically, stainless steel), ceramic, or plastic.As plastic, a fiberglass-reinforced plastics (FRP) plate, a polyvinylfluoride (PVF) film, a polyester film, or an acrylic resin film can beused.

A columnar spacer 4035 is obtained by selective etching of an insulatinglayer and is provided in order to control the distance (a cell gap)between the pixel electrode layer 4030 and the counter electrode layer4031. Note that a spherical spacer may be used. The counter electrodelayer 4031 is electrically connected to a common potential line providedover the same substrate as the substrate of the thin film transistor4010. With the use of the common connection portion, the counterelectrode layer 4031 can be electrically connected to the commonpotential line through conductive particles provided between the pair ofsubstrates. Note that the conductive particles are contained in thesealant 4005.

Alternatively, a liquid crystal showing a blue phase which leads to theneed of an alignment film may be used. A blue phase is one of the liquidcrystal phases, which is generated just before a cholesteric phasechanges into an isotropic phase while temperature of cholesteric liquidcrystal is increased. Since the blue phase is only generated within anarrow range of temperatures, a liquid crystal composition containing achiral agent at 5 wt % or more is used for the liquid crystal layer 4008in order to improve the temperature range. The liquid crystalcomposition which includes a liquid crystal showing a blue phase and achiral agent has a small response time of 1 milliseconds or less, hasoptical isotropy, which makes the alignment process unneeded, and has asmall viewing angle dependence.

An embodiment of the present invention can also be applied to areflective liquid crystal display device or a transflective liquidcrystal display device, as well as a transmissive liquid crystal displaydevice.

An example of the liquid crystal display device will be described inwhich a polarizing plate is provided on the outer side of the substrate(on the viewer side) and a coloring layer (color filter) and anelectrode layer used for a display element are provided on the innerside of the substrate in this order; however, the polarizing plate maybe provided on the inner side of the substrate. The stack structure ofthe polarizing plate and the coloring layer is not limited to thatdescribed in Embodiment 11 and may be set as appropriate depending onmaterials of the polarizing plate and the coloring layer or conditionsof manufacturing steps. Furthermore, a light-blocking layer serving as ablack matrix may be provided.

Over the thin film transistors 4010 and 4011, the protection insulatinglayer 4020 is formed. The protection insulating layer 4020 is formedusing an inorganic insulating film which includes impurities such asmoisture, a hydrogen ion, and OH⁻ as less as possible and blocks entryof them from the outside; specifically, a silicon nitride film, analuminum nitride film, a silicon nitride oxide film, an aluminumoxynitride film, or the like is used. The protection insulating layer4020 is an insulating film having light-transmitting property. In thisembodiment, a silicon nitride film is formed by a PCVD method as theprotection insulating layer 4020.

The insulating layer 4021 is formed as the planarization insulatinglayer. As the insulating layer 4021, an organic material having heatresistance such as polyimide, acrylic, benzocyclobutene, polyamide, orepoxy can be used. Other than such organic materials, it is alsopossible to use a low-dielectric constant material (a low-k material), asiloxane-based resin, phosphosilicate glass (PSG), borophosphosilicateglass (BPSG), or the like. Note that the insulating layer 4021 may beformed by stacking a plurality of insulating layers formed using any ofthese materials.

Note that a siloxane-based resin is a resin formed using a siloxanematerial as a starting material and having a Si—O—Si bond. Thesiloxane-based resin may include as a substituent an organic group(e.g., an alkyl group or an aryl group) or a fluoro group. The organicgroup may include a fluoro group.

There is no particular limitation on the method for forming theinsulating layer 4021; depending on a material thereof, a method such asa sputtering method, an SOG method, a spin coating method, a dippingmethod, a spray coating method, a droplet discharge method (e.g., aninkjet method, screen printing, offset printing, or the like), a tool(equipment) such as a doctor knife, a roll coater, a curtain coater, aknife coater or the like can be used. The baking step of the insulatinglayer 4021 also serves as the annealing step of the semiconductor layer,whereby a semiconductor device can be manufactured efficiently.

The pixel electrode layer 4030 and the counter electrode layer 4031 eachcan be formed using a light-transmitting conductive material such asindium oxide containing tungsten oxide, indium zinc oxide containingtungsten oxide, indium oxide containing titanium oxide, indium tin oxidecontaining titanium oxide, indium tin oxide (hereinafter referred to asITO), indium zinc oxide, or indium tin oxide to which silicon oxide isadded.

A conductive composition containing a conductive high molecule (alsoreferred to as a conductive polymer) can be used for the pixel electrodelayer 4030 and the counter electrode layer 4031. It is preferable thatthe pixel electrode formed using the conductive composition preferablyhave a sheet resistance of 10000 ohms per square or less and atransmittance of 70% or more at a wavelength of 550 nm Further, it ispreferable that the resistivity of the conductive high moleculecontained in the conductive composition be 0.1 Ω·cm or less.

As the conductive high molecule, a so-called π-electron conjugatedconductive polymer can be used. As examples thereof, there arepolyaniline or a derivative thereof, polypyrrole or a derivativethereof, polythiophene or a derivative thereof, or a copolymer of two ormore kinds of them, and the like.

In addition, a variety of signals and potentials are supplied to thesignal line driver circuit 4003 that is formed separately, and the scanline driver circuit 4004 or the pixel portion 4002 from an FPC 4018.

A connection terminal electrode 4015 is formed using the same conductivelayer as the pixel electrode layer 4030 included in the liquid crystalelement 4013, and a terminal electrode 4016 is formed using the sameconductive layer as a source and drain electrode layers of the thin filmtransistor 4011.

The connection terminal electrode 4015 is electrically connected to aterminal included in the FPC 4018 through an anisotropic conductivelayer 4019.

Note that FIGS. 20A1, 20A2 and 20B illustrate an example in which thesignal line driver circuit 4003 is formed separately and mounted on thefirst substrate 4001; however, Embodiment 11 is not limited to thisstructure. The scan line driver circuit may be separately formed andthen mounted, or only part of the signal line driver circuit or part ofthe scan line driver circuit may be separately formed and then mounted.

FIG. 21 shows an example in which a liquid crystal display module isformed as a semiconductor device using a TFT substrate 2600 which ismanufactured according to the manufacturing method disclosed in thisspecification.

FIG. 21 illustrates an example of a liquid crystal display module, inwhich the TFT substrate 2600 and a counter substrate 2601 are bonded toeach other with a sealant 2602, and a pixel portion 2603 including a TFTor the like, a display element 2604 including a liquid crystal layer,and a coloring layer 2605 are provided between the substrates to form adisplay region. The coloring layer 2605 is necessary to perform colordisplay. In the case of the RGB system, respective coloring layerscorresponding to colors of red, green, and blue are provided forrespective pixels. Polarizing plates 2606 and 2607 and a diffusion plate2613 are provided outside the TFT substrate 2600 and the countersubstrate 2601. A light source includes a cold cathode tube 2610 and areflective plate 2611. A circuit board 2612 is connected to a wiringcircuit portion 2608 of the TFT substrate 2600 through a flexible wiringboard 2609 and includes an external circuit such as a control circuit ora power source circuit. The polarizing plate and the liquid crystallayer may be stacked with a retardation plate interposed therebetween.

For the liquid crystal display module, a TN (twisted nematic) mode, anIPS (in-plane-switching) mode, an FFS (fringe field switching) mode, anMVA (multi-domain vertical alignment) mode, a PVA (patterned verticalalignment) mode, an ASM (axially symmetric aligned micro-cell) mode, anOCB (optical compensated birefringence) mode, an FLC (ferroelectricliquid crystal) mode, an AFLC (antiferroelectric liquid crystal) mode,or the like can be used.

Through the above process, a highly reliable liquid crystal displaypanel can be manufactured as a semiconductor device.

Embodiment 11 can be implemented in appropriate combination with anyother embodiment described herein.

Embodiment 12

In Embodiment 12, an example of an electronic paper will be described asa semiconductor device of an embodiment of the present invention.

The electronic paper is also referred to as an electrophoretic displaydevice (an electrophoretic display) and is advantageous in that it hasthe same level of readability as plain paper, it has lower powerconsumption than other display devices, and it can be made thin andlightweight.

Electrophoretic displays can have various modes. Electrophoreticdisplays contain a plurality of microcapsules dispersed in a solvent ora solute, each microcapsule containing first particles which arepositively charged and second particles which are negatively charged. Byapplying an electric field to the microcapsules, the particles in themicrocapsules move in opposite directions to each other and only thecolor of the particles gathering on one side is displayed. Note that thefirst particles and the second particles each contain pigment and do notmove without an electric field. Moreover, the first particles and thesecond particles have different colors (either one of which may becolorless).

Thus, an electrophoretic display is a display that utilizes a so-calleddielectrophoretic effect by which a substance having a high dielectricconstant moves to a high-electric field region. An electrophoreticdisplay device does not involve a polarizing plate which is involved inthe case of a liquid crystal display device.

A solution in which the above microcapsules are dispersed in a solventis referred to as electronic ink. This electronic ink can be printed ona surface of glass, plastic, cloth, paper, or the like. Furthermore, byusing a color filter or particles that have a pigment, color display canalso be achieved.

Further, a plurality of the above microcapsules is arranged asappropriate over an active matrix substrate so as to be interposedbetween two electrodes, so that an active matrix display device can becompleted, and display can be performed by application of an electricfield to the microcapsules. For example, the active matrix substrateobtained by using any of the thin film transistors described in any ofEmbodiments 1 to 9 can be used.

The first particles and the second particles in the microcapsules mayeach be formed using a single material selected from a conductivematerial, an insulating material, a semiconductor material, a magneticmaterial, a liquid crystal material, a ferroelectric material, anelectroluminescent material, an electrochromic material, and amagnetophoretic material, or a composite material of any of these.

FIG. 22 illustrates active matrix electronic paper as an example of asemiconductor device. A thin film transistor 581 used in thesemiconductor device can be manufactured in a manner similar to that ofthe thin film transistor described in Embodiment 1 and is a highlyreliable thin film transistor including an oxide semiconductor layer.The thin film transistor described in any of Embodiments 2 to 9 can alsobe used as the thin film transistor 581 of Embodiment 12.

The electronic paper in FIG. 22 is an example of a display device usinga twisting ball display system. The twisting ball display system refersto a method in which spherical particles each colored in black and whiteare arranged between a first electrode layer and a second electrodelayer which are electrode layers used for a display element, and apotential difference is generated between the first electrode layer andthe second electrode layer to control orientation of the sphericalparticles, so that display is performed.

The thin film transistor 581 formed over a substrate 580 is abottom-gate thin film transistor and is covered with an insulating layer583 which is in contact with a semiconductor layer. A source or drainelectrode layer of the thin film transistor 581 is in contact with afirst electrode layer 587 through an opening formed in a first electrodelayer 587, an insulating layer 583, and an insulating layer 585, wherebythe thin film transistor 581 is electrically connected to the firstelectrode layer 587. Between the first electrode layer 587 and a secondelectrode layer 588 formed over a substrate 596, spherical particles 589each having a black region 590 a, a white region 590 b, and a cavity 594around the regions which is filled with liquid are provided. A spacearound the spherical particles 589 is filled with a filler 595 such as aresin. The first electrode layer 587 corresponds to a pixel electrode,and the second electrode layer 588 corresponds to a common electrode.The second electrode layer 588 is electrically connected to a commonpotential line provided over the same substrate as the substrate of thethin film transistor 581. With the use of a common connection portion,the second electrode layer 588 can be electrically connected to thecommon potential line through conductive particles provided between thesubstrates 580 and 596.

Instead of the twisting ball, an electrophoretic element can also beused. A microcapsule having a diameter of about 10 μm to 200 μm in whichtransparent liquid, positively-charged white microparticles, andnegatively-charged black microparticles are encapsulated, is used. Inthe microcapsule which is provided between the first electrode layer andthe second electrode layer, when an electric field is applied betweenthe first electrode layer and the second electrode layer, the whitemicroparticles and the black microparticles move to opposite sides fromeach other, so that white or black can be displayed. A display elementusing this principle is an electrophoretic display element and isgenerally called electronic paper. The electrophoretic display elementhas higher reflectance than a liquid crystal display element, and thus,an auxiliary light is unnecessary, power consumption is low, and adisplay portion can be recognized in a dim place. In addition, even whenpower is not supplied to the display portion, an image which has beendisplayed once can be maintained. Accordingly, a displayed image can bestored even if a semiconductor device having a display function (whichmay be referred to simply as a display device or a semiconductor deviceprovided with a display device) is distanced from an electric wavesource.

Through the above process, a highly reliable electronic paper can bemanufactured as a semiconductor device.

Embodiment 12 can be implemented in appropriate combination with anyother embodiment described herein.

Embodiment 13

An example of a light-emitting display device will be described as asemiconductor device. As a display element included in a display device,a light-emitting element utilizing electroluminescence is described inEmbodiment 13. Light-emitting elements utilizing electroluminescence areclassified according to whether a light-emitting material is an organiccompound or an inorganic compound. In general, the former is referred toas an organic EL element, and the latter is referred to as an inorganicEL element.

In an organic EL element, by application of a voltage to alight-emitting element, electrons and holes are separately injected froma pair of electrodes into a layer containing a light-emitting organiccompound, and current flows. Then, the carriers (electrons and holes)recombine, so that the light-emitting organic compound is excited. Thelight-emitting organic compound returns to a ground state from theexcited state, thereby emitting light. Owing to such a mechanism, thislight-emitting element is referred to as a current-excitationlight-emitting element.

The inorganic EL elements are classified according to their elementstructures into a dispersion-type inorganic EL element and a thin-filminorganic EL element. A dispersion-type inorganic EL element has alight-emitting layer where particles of a light-emitting material aredispersed in a binder, and its light emission mechanism isdonor-acceptor recombination type light emission which utilizes a donorlevel and an acceptor level. A thin-film inorganic EL element has astructure where a light-emitting layer is sandwiched between dielectriclayers, which are further sandwiched between electrodes, and its lightemission mechanism is localized type light emission that utilizesinner-shell electron transition of metal ions. Description is made usingan organic EL element as a light-emitting element in Embodiment 13.

FIG. 23 illustrates an example of a pixel configuration as an example ofa semiconductor device which can be driven by a digital time grayscalemethod.

The structure and operation of the pixel which can be driven by adigital time grayscale method will be described. An example is describedin Embodiment 13 in which one pixel includes two n-channel transistorsusing an oxide semiconductor layer in a channel formation region.

A pixel 6400 includes a switching transistor 6401, a transistor 6402 fordriving a light-emitting element, a light-emitting element 6404, and acapacitor 6403. A gate of the switching transistor 6401 is connected toa scan line 6406, a first electrode (one of a source electrode and adrain electrode) of the switching transistor 6401 is connected to asignal line 6405, and a second electrode (the other of the sourceelectrode and the drain electrode) of the switching transistor 6401 isconnected to a gate of the transistor 6402 for driving thelight-emitting element. The gate of the transistor 6402 for driving thelight-emitting element is connected to a power supply line 6407 throughthe capacitor 6403, a first electrode of the driving transistor 6402 isconnected to the power supply line 6407, and a second electrode of thetransistor 6402 for driving the light-emitting element is connected to afirst electrode (pixel electrode) of the light-emitting element 6404. Asecond electrode of the light-emitting element 6404 corresponds to acommon electrode 6408. The common electrode 6408 is electricallyconnected to a common potential line provided over the same substrate.

Note that the second electrode (common electrode 6408) of thelight-emitting element 6404 is set to a low power supply potential. Thelow power supply potential is lower than a high power supply potentialwhich is supplied to the power supply line 6407. For example, GND or 0 Vmay be set as the low power supply potential. The difference between thehigh power supply potential and the low power supply potential isapplied to the light-emitting element 6404 so that current flows throughthe light-emitting element 6404, whereby the light-emitting element 6404emits light. Thus, each potential is set so that the difference betweenthe high power supply potential and the low power supply potential isgreater than or equal to a forward threshold voltage of thelight-emitting element 6404.

When the gate capacitance of the transistor 6402 for driving thelight-emitting element is used as a substitute for the capacitor 6403,the capacitor 6403 can be omitted. The gate capacitance of thetransistor 6402 for driving the light-emitting element may be formedbetween a channel region and a gate electrode.

Here, in the case of using a voltage-input voltage driving method, avideo signal is input to the gate of the transistor 6402 for driving thelight-emitting element to make the transistor 6402 for driving thelight-emitting element completely turn on or off. That is, thetransistor 6402 for driving the light-emitting element operates in alinear region, and thus, a voltage higher than the voltage of the powersupply line 6407 is applied to the gate of the transistor 6402 fordriving the light-emitting element. Note that a voltage greater than orequal to (power supply line voltage+V_(th) of the transistor 6402 fordriving the light-emitting element) is applied to the signal line 6405.

In the case of using an analog grayscale method instead of the digitaltime grayscale method, the same pixel configuration as in FIG. 23 can beemployed by changing input of signals.

In the case of using the analog grayscale method, a voltage greater thanor equal to (forward voltage of the light-emitting element 6404+V_(th)of the transistor 6402 for driving the light-emitting element) isapplied to the gate of the transistor 6402 for driving thelight-emitting element. The forward voltage of the light-emittingelement 6404 refers to a voltage to obtain a desired luminance, andincludes at least a forward threshold voltage. By inputting a videosignal to enable the transistor 6402 for driving the light-emittingelement to operate in a saturation region, current can be supplied tothe light-emitting element 6404. In order that the transistor 6402 fordriving the light-emitting element can operate in the saturation region,the potential of the power supply line 6407 is set to be higher than agate potential of the transistor 6402 for driving the light-emittingelement. Since the video signal is an analog signal, current inaccordance with the video signal flows in the light-emitting element6404, and the analog grayscale method can be performed.

The pixel configuration is not limited to that illustrated in FIG. 23.For example, a switch, a resistor, a capacitor, a transistor, a logiccircuit, or the like can be added to the pixel shown in FIG. 23.

Next, structures of the light-emitting element will be described withreference to FIGS. 24A to 24C. In Embodiment 13, a cross-sectionalstructure of a pixel will be described by taking an n-channel TFT fordriving a light-emitting element as an example. TFTs 7001, 7011, and7021 which are TFTs for driving light-emitting elements used forsemiconductor devices illustrated in FIGS. 24A to 24C can bemanufactured in a manner similar to that of the thin film transistorused in a pixel, which is described in Embodiment 1. The TFTs 7001,7011, and 7021 are highly reliable thin film transistors each includingan oxide semiconductor layer. Alternatively, the thin film transistorused in a pixel, which is described in any of Embodiments 2 to 9 can beemployed as any of the TFTs 7001, 7011, and 7021.

In order to extract light emitted from the light-emitting element, atleast one of the anode and the cathode transmits light. A thin filmtransistor and a light-emitting element are formed over a substrate. Alight-emitting element can have a top emission structure in which lightis extracted through the surface opposite to the substrate, a bottomemission structure in which light is extracted through the surface onthe substrate side, or a dual emission structure in which light isextracted through the surface opposite to the substrate and the surfaceon the substrate side. The above-described pixel configuration can beapplied to a light-emitting element having any of these emissionstructures.

A light-emitting element having a top emission structure will bedescribed with reference to FIG. 24A.

FIG. 24A is a cross-sectional view of a pixel in the case where the TFT7001 for driving the light-emitting element is of an n-type and light isemitted from a light-emitting element 7002 to an anode 7005 side. InFIG. 24A, a cathode 7003 of the light-emitting element 7002 iselectrically connected to the TFT 7001 for driving the light-emittingelement, and a light-emitting layer 7004 and the anode 7005 are stackedin this order over the cathode 7003. The cathode 7003 can be made of avariety of conductive materials as long as they have a low work functionand reflect light. For example, it is preferable to use Ca, Al, CaF,MgAg, AlLi, or the like. The light-emitting layer 7004 may be formedusing a single layer or a plurality of layers stacked. When thelight-emitting layer 7004 is formed using a plurality of layers, thelight-emitting layer 7004 is formed by stacking an electron-injectionlayer, an electron-transport layer, a light-emitting layer, ahole-transport layer, and a hole-injection layer in this order over thecathode 7003. Note that not all of these layers need to be provided. Theanode 7005 is made using a light-transmitting conductive material suchas indium oxide including tungsten oxide, indium zinc oxide includingtungsten oxide, indium oxide including titanium oxide, indium tin oxideincluding titanium oxide, indium tin oxide (hereinafter referred to asITO), indium zinc oxide, or indium tin oxide to which silicon oxide isadded.

Further, a partition 7009 is provided over the cathode 7003. Thepartition 7009 is formed using an organic resin film of polyimide,acrylic, polyamide, epoxy, or the like, an inorganic insulating film, ororganic polysiloxane. It is preferable that the partition 7009 be formedusing a photosensitive resin material so that a sidewall of thepartition 7009 is formed as a tilted surface with continuous curvature.In the case where a photosensitive resin material is used for thepartition 7009, a step of forming a resist mask can be omitted.

The light-emitting element 7002 corresponds to a region where thelight-emitting layer 7004 is sandwiched between the cathode 7003 and theanode 7005. In the case of the pixel illustrated in FIG. 24A, light isemitted from the light-emitting element 7002 to the anode 7005 side asindicated by an arrow.

Next, a light-emitting element having a bottom emission structure willbe described with reference to FIG. 24B. FIG. 24B is a cross-sectionalview of a pixel in the case where the TFT 7011 for driving thelight-emitting element is of an n-type and light is emitted from alight-emitting element 7012 to a cathode 7013 side. In FIG. 24B, thecathode 7013 of the light-emitting element 7012 is formed over alight-transmitting conductive layer 7017 which is electrically connectedto the TFT 7011 for driving the light-emitting element, and alight-emitting layer 7014 and an anode 7015 are stacked in this orderover the cathode 7013. Note that a light-blocking film 7016 forreflecting or blocking light may be formed to cover the anode 7015 whenthe anode 7015 has a light-transmitting property. For the cathode 7013,various materials can be used, like in the case of FIG. 24A, as long asthey are conductive materials having a low work function. Note that thecathode 7013 is formed to have a thickness that can transmit light(preferably, about 5 to 30 nm). For example, an aluminum film with athickness of 20 nm can be used as the cathode 7013. Similarly to thecase of FIG. 24A, the light-emitting layer 7014 may be formed usingeither a single layer or a plurality of layers stacked. The anode 7015is not required to transmit light, but can be formed using alight-transmitting conductive material like in the case of FIG. 24A. Asthe light-blocking film 7016, a metal which reflects light can be usedfor example; however, it is not limited to a metal film. For example, aresin to which black pigments are added can also be used.

Further, a partition 7019 is provided over the conductive layer 7017.The partition 7019 is formed using an organic resin film of polyimide,acrylic, polyamide, epoxy, or the like, an inorganic insulating film, ororganic polysiloxane. It is preferable that the partition 7019 be formedusing a photosensitive resin material so that a sidewall of thepartition 7019 is formed as a tilted surface with continuous curvature.In the case where a photosensitive resin material is used for thepartition 7019, a step of forming a resist mask can be omitted.

The light-emitting element 7012 corresponds to a region where thelight-emitting layer 7014 is sandwiched between the cathode 7013 and theanode 7015. In the case of the pixel illustrated in FIG. 24B, light isemitted from the light-emitting element 7012 to the cathode 7013 side asindicated by an arrow.

Next, a light-emitting element having a dual emission structure will bedescribed with reference to FIG. 24C. In FIG. 24C, a cathode 7023 of alight-emitting element 7022 is formed over a light-transmittingconductive layer 7027 which is electrically connected to the TFT 7021for driving the light-emitting element, and a light-emitting layer 7024and an anode 7025 are stacked in this order over the cathode 7023. Likein the case of FIG. 24A, the cathode 7023 can be formed using a varietyof conductive materials as long as they have a low work function. Notethat the cathode 7023 is formed using a thickness that can transmitlight. For example, an aluminum film with a thickness of 20 nm can beused as the cathode 7023. Like in FIG. 24A, the light-emitting layer7024 may be formed as either a single layer or a plurality of layersstacked. The anode 7025 can be formed using a light-transmittingconductive material like in the case of FIG. 24A.

Further, a partition 7029 is provided over the conductive layer 7027.The partition 7029 is formed using an organic resin film of polyimide,acrylic, polyamide, epoxy, or the like, an inorganic insulating film, ororganic polysiloxane. It is preferable that the partition 7029 be formedusing a photosensitive resin material so that a sidewall of thepartition 7029 is formed as a tilted surface with continuous curvature.In the case where a photosensitive resin material is used for thepartition 7029, a step of forming a resist mask can be omitted.

The light-emitting element 7022 corresponds to a region where thecathode 7023, the light-emitting layer 7024, and the anode 7025 overlapone another. In the case of the pixel illustrated in FIG. 24C, light isemitted from the light-emitting element 7022 to both the anode 7025 sideand the cathode 7023 side as indicated by arrows.

Although an organic EL element is described in Embodiment 13 as alight-emitting element, an inorganic EL element can be provided as alight-emitting element as well.

The example is described in which a thin film transistor (a TFT fordriving a light-emitting element) which controls the driving of alight-emitting element is electrically connected to the light-emittingelement; however, a structure may be employed in which a TFT for currentcontrol is connected between the TFT for driving the light-emittingelement and the light-emitting element.

Note that the structure of the semiconductor device is not limited tothose illustrated in FIGS. 24A to 24C and can be modified in variousways based on the spirit of techniques described in this specification.

Next, the appearance and a cross section of a light-emitting displaypanel (also referred to as a light-emitting panel), which is anembodiment of the semiconductor device, will be described with referenceto FIGS. 25A and 25B. FIG. 25A is a plan view of a panel in which a thinfilm transistor and a light-emitting element are sealed between a firstsubstrate and a second substrate with a sealant. FIG. 25B is across-sectional diagram taken along line H-I of FIG. 25A.

A sealant 4505 is provided to surround a pixel portion 4502, signal linedriver circuits 4503 a and 4503 b, and scan line driver circuits 4504 aand 4504 b, which are provided over a first substrate 4501. In addition,a second substrate 4506 is provided over the pixel portion 4502, thesignal line driver circuits 4503 a and 4503 b, and the scan line drivercircuits 4504 a and 4504 b. Accordingly, the pixel portion 4502, thesignal line driver circuits 4503 a and 4503 b, and the scan line drivercircuits 4504 a and 4504 b are sealed together with a filler 4507, bythe first substrate 4501, the sealant 4505, and the second substrate4506. It is preferable that a display device be thus packaged (sealed)with a protective film (such as a bonding film or an ultraviolet curableresin film) or a cover material with high air-tightness and littledegasification so that the display device is not exposed to the outsideair.

The pixel portion 4502, the signal line driver circuits 4503 a and 4503b, and the scan line driver circuits 4504 a and 4504 b provided over thefirst substrate 4501 each include a plurality of thin film transistors,and a thin film transistor 4510 included in the pixel portion 4502 and athin film transistor 4509 included in the signal line driver circuit4503 a are illustrated as an example in FIG. 25B.

As the thin film transistors 4509 and 4510, the highly reliable thinfilm transistor including the oxide semiconductor layer described inEmbodiment 3 can be employed. Alternatively, any of the thin filmtransistors described in Embodiments 1 and 2 can be employed. The thinfilm transistors 4509 and 4510 are n-channel thin film transistors inthis embodiment.

Further, a protection insulating layer 4543 is formed over the thin filmtransistors 4509 and 4510. The protection insulating layer 4543 isformed using an inorganic insulating film which includes impurities suchas moisture, a hydrogen ion, and OH⁻ as less as possible and blocksentry of them from the outside; specifically, a silicon nitride film, analuminum nitride film, a silicon nitride oxide film, an aluminumoxynitride film, or the like is used. The protection insulating layer4543 is an insulating film having light-transmitting property. In thisembodiment, a silicon nitride film is formed by a PCVD method as theprotection insulating layer 4543.

The insulating layer 4544 is formed as a planarization insulating layer.As the insulating layer 4544, an organic material having heat resistancesuch as polyimide, acrylic, benzocyclobutene, polyamide, or epoxy can beused. Other than such organic materials, it is also possible to use alow-dielectric constant material (a low-k material), a siloxane-basedresin, phosphosilicate glass (PSG), borophosphosilicate glass (BPSG), orthe like. Note that the insulating layer 4544 may be formed by stackinga plurality of insulating layers formed using any of these materials. Inthis embodiment, acrylic is used as the insulating layer 4544.

Moreover, reference numeral 4511 denotes a light-emitting element. Afirst electrode layer 4517 that is a pixel electrode included in thelight-emitting element 4511 is electrically connected to a sourceelectrode layer or a drain electrode layer of the thin film transistor4510. Note that a structure of the light-emitting element 4511 is notlimited to the stack structure described in Embodiment 13, whichincludes the first electrode layer 4517, an electroluminescent layer4512, and a second electrode layer 4513. The structure of thelight-emitting element 4511 can be changed as appropriate depending onthe direction in which light is extracted from the light-emittingelement 4511, or the like.

A partition 4520 is formed using an organic resin film, an inorganicinsulating film, or organic polysiloxane. It is preferable that thepartition 4520 be formed using a photosensitive material to have anopening over the first electrode layer 4517 so that a sidewall of theopening is formed as an inclined surface with continuous curvature.

The electroluminescent layer 4512 may be formed with a single layer or aplurality of layers stacked.

An oxide insulating layer may be formed over the second electrode layer4513 and the partition 4520 in order to prevent hydrogen, moisture,carbon dioxide, or the like from entering the light-emitting element4511.

A variety of signals and potentials are supplied to the signal linedriver circuits 4503 a and 4503 b, the scan line driver circuits 4504 aand 4504 b, or the pixel portion 4502 from FPCs 4518 a and 4518 b.

A connection terminal electrode 4515 is formed using the same conductivelayer as the first electrode layer 4517 included in the light-emittingelement 4511, and a terminal electrode 4516 is formed using the sameconductive layer as the source and drain electrode layers included inthe thin film transistor 4509.

The connection terminal electrode 4515 is electrically connected to aterminal of the FPC 4518 a through an anisotropic conductive layer 4519.

As the second substrate 4506 located in the direction in which light isextracted from the light-emitting element 4511 needs to have alight-transmitting property. In that case, a light-transmitting materialsuch as a glass plate, a plastic plate, a polyester film, or an acrylicfilm is used.

As the filler 4507, an ultraviolet curable resin or a thermosettingresin can be used, as well as an inert gas such as nitrogen or argon.For example, PVC (polyvinyl chloride), acrylic, polyimide, an epoxyresin, a silicone resin, PVB (polyvinyl butyral), or EVA (ethylene vinylacetate) can be used. For example, nitrogen can be used as the filler.

If needed, an optical film, such as a polarizing plate, a circularlypolarizing plate (including an elliptically polarizing plate), aretardation plate (a quarter-wave plate or a half-wave plate), or acolor filter, may be provided as appropriate on a light-emitting surfaceof the light-emitting element. Furthermore, the polarizing plate or thecircularly polarizing plate may be provided with an anti-reflectionfilm. For example, anti-glare treatment by which reflected light can bediffused by roughness of the surface so as to reduce the glare can beperformed.

The signal line driver circuits 4503 a and 4503 b and the scan linedriver circuits 4504 a and 4504 b may be mounted as driver circuitsformed using a single crystal semiconductor layer or a polycrystallinesemiconductor layer over a substrate separately prepared. Alternatively,only the signal line driver circuits or part thereof, or only the scanline driver circuits or part thereof may be separately formed andmounted. Embodiment 13 is not limited to the structure illustrated inFIGS. 25A and 25B.

Through the above process, a highly reliable light-emitting displaypanel (light-emitting panel) as a semiconductor device can bemanufactured.

Embodiment 13 can be implemented in appropriate combination with anyother embodiment described herein.

Embodiment 14

A semiconductor device disclosed in this specification can be applied asan electronic paper. An electronic paper can be used for electronicappliances in a variety of fields as long as they can display data. Forexample, an electronic paper can be applied to an e-book reader(electronic book), a poster, an advertisement in a vehicle such as atrain, or displays of various cards such as a credit card. An example ofthe electronic appliances is illustrated in FIG. 26.

FIG. 26 illustrates an example of an e-book reader 2700. For example,the e-book reader 2700 includes a housing 2701 and a housing 2703. Thehousing 2701 and the housing 2703 are combined with a hinge 2711 so thatthe e-book reader 2700 can be opened and closed with the hinge 2711 asan axis. With such a structure, the e-book reader 2700 can operate likea paper book.

A display portion 2705 and a display portion 2707 are incorporated inthe housing 2701 and the housing 2703, respectively. The display portion2705 and the display portion 2707 may display one image or differentimages. In the case where the display portion 2705 and the displayportion 2707 display different images, for example, text can bedisplayed on a display portion on the right side (the display portion2705 in FIG. 26) and graphics can be displayed on a display portion onthe left side (the display portion 2707 in FIG. 26).

FIG. 26 illustrates an example in which the housing 2701 is providedwith an operation portion and the like. For example, the housing 2701 isprovided with a power switch 2721, an operation key 2723, a speaker2725, and the like. With the operation key 2723, pages can be turned.Note that a keyboard, a pointing device, and the like may be provided onthe same surface as the display portion of the housing. Furthermore, anexternal connection terminal (an earphone terminal, a USB terminal, aterminal that can be connected to various cables such as an AC adapterand a USB cable, or the like), a recording medium insertion portion, andthe like may be provided on the back surface or the side surface of thehousing. Moreover, the e-book reader 2700 may have a function of anelectronic dictionary.

The e-book reader 2700 may have a structure capable of wirelesslytransmitting and receiving data. Through wireless communication, desiredbook data or the like can be purchased and downloaded from an electronicbook server.

Embodiment 15

A semiconductor device disclosed in this specification can be applied toa variety of electronic appliances (including amusement machines).Examples of electronic appliances include television sets (also referredto as televisions or television receivers), monitor of computers or thelike, cameras such as digital cameras or digital video cameras, digitalphoto frames, cellular phones (also referred to as mobile phones ormobile phone sets), portable game consoles, portable informationterminals, audio reproducing devices, large-sized game machines such aspachinko machines, and the like.

FIG. 27A illustrates an example of a television set 9600. In thetelevision set 9600, a display portion 9603 is incorporated in a housing9601. Images can be displayed on the display portion 9603. In thisexample, the housing 9601 is supported by a stand 9605.

The television set 9600 can be operated with an operation switch of thehousing 9601 or a separate remote controller 9610. Channels and volumecan be controlled with an operation key 9609 of the remote controller9610 so that an image displayed on the display portion 9603 can becontrolled. Furthermore, the remote controller 9610 may be provided witha display portion 9607 for displaying data output from the remotecontroller 9610.

Note that the television set 9600 is provided with a receiver, a modem,and the like. With the receiver, a general television broadcast can bereceived. Furthermore, when the television set 9600 is connected to acommunication network by wired or wireless connection via the modem,one-way (from transmitter to receiver) or two-way (between transmitterand receiver, between receivers, or the like) data communication can beperformed.

FIG. 27B illustrates an example of a digital photo frame 9700. Forexample, in the digital photo frame 9700, a display portion 9703 isincorporated in a housing 9701. Various images can be displayed on thedisplay portion 9703. For example, the display portion 9703 can displaydata of an image shot by a digital camera or the like to function as anormal photo frame.

Note that the digital photo frame 9700 is provided with an operationportion, an external connection portion (a USB terminal, a terminal thatcan be connected to various cables such as a USB cable, or the like), arecording medium insertion portion, and the like. Although they may beprovided on the same surface as the display portion, it is preferable toprovide them on the side surface or the back surface for the design ofthe digital photo frame 9700. For example, a memory storing data of animage shot by a digital camera is inserted in the recording mediuminsertion portion of the digital photo frame 9700, whereby the imagedata can be downloaded and displayed on the display portion 9703.

The digital photo frame 9700 may have a structure capable of wirelesslytransmitting and receiving data. Through wireless communication, desiredimage data can be downloaded to be displayed.

FIG. 28A illustrates a portable amusement machine including twohousings: a housing 9881 and a housing 9891. The housings 9881 and 9891are connected with a connection portion 9893 so as to be opened andclosed. A display portion 9882 and a display portion 9883 areincorporated in the housing 9881 and the housing 9891, respectively. Inaddition, the portable amusement machine illustrated in FIG. 28Aincludes a speaker portion 9884, a recording medium insertion portion9886, an LED lamp 9890, an input means (an operation key 9885, aconnection terminal 9887, a sensor 9888 (a sensor having a function ofmeasuring force, displacement, position, speed, acceleration, angularvelocity, rotational frequency, distance, light, liquid, magnetism,temperature, chemical substance, sound, time, hardness, electric field,current, voltage, electric power, radiation, flow rate, humidity,gradient, oscillation, odor, or infrared rays), and a microphone 9889),and the like. It is needless to say that the structure of the portableamusement machine is not limited to the above and any other structureprovided with at least a semiconductor device disclosed in thisspecification can be employed. The portable amusement machine mayinclude other accessory equipment as appropriate. The portable amusementmachine illustrated in FIG. 28A has a function of reading a program ordata stored in a recording medium to display it on the display portion,and a function of sharing information with another portable amusementmachine by wireless communication. Note that the portable amusementmachine illustrated in FIG. 28A can have various functions withoutlimitation to the above.

FIG. 28B illustrates an example of a slot machine 9900 which is alarge-sized amusement machine. In the slot machine 9900, a displayportion 9903 is incorporated in a housing 9901. In addition, the slotmachine 9900 includes an operation means such as a start lever or a stopswitch, a coin slot, a speaker, and the like. It is needless to say thatthe structure of the slot machine 9900 is not limited to the above andany other structure provided with at least a semiconductor devicedisclosed in this specification may be employed. The slot machine 9900may include other accessory equipment as appropriate.

FIG. 29A is a perspective view illustrating an example of a portablecomputer.

In the portable computer of FIG. 29A, a top housing 9301 having adisplay portion 9303 and a bottom housing 9302 having a keyboard 9304can overlap each other by closing a hinge unit which connects the tophousing 9301 and the bottom housing 9302. The portable computer of FIG.29A can be convenient for carrying, and in the case of using thekeyboard for input, the hinge unit is opened and the user can inputlooking at the display portion 9303.

The bottom housing 9302 includes a pointing device 9306 with which datainput can be performed, in addition to the keyboard 9304. Further, whenthe display portion 9303 is a touch input panel, data input can beperformed by touching part of the display portion. The bottom housing9302 includes an arithmetic function portion such as a CPU or hard disk.In addition, the bottom housing 9302 includes another device, forexample, an external connection port 9305 into which a communicationcable conformable to communication standards of a USB is inserted.

The top housing 9301 further includes a display portion 9307 which canbe housed therein by sliding toward the inside of the top housing 9301,thereby realizing a large display screen. In addition, the user canadjust the orientation of a screen of the display portion 9307 which canbe kept in the top housing 9301. When the display portion 9307 which canbe housed the top housing 9301 is a touch input panel, data input can beperformed by touching part of the display portion 9307 which can behoused in the top housing 9301.

The display portion 9303 or the display portion 9307 which can be housedin the top housing 9301 are formed using an image display device of aliquid crystal display panel, a light-emitting display panel such as anorganic light-emitting element or an inorganic light-emitting element,or the like.

In addition, the portable computer of FIG. 29A can be provided with areceiver and the like and can receive a television broadcast to displayan image on the display portion. A television broadcast can be watchedon the whole screen of the display portion 9307 exposed by sliding withthe hinge unit which connects the top housing 9301 and the bottomhousing 9302 closed. In that case, the hinge unit is not opened anddisplay is not performed on the display portion 9303, and operation ofonly a circuit for displaying the television broadcast is performed;therefore, power consumption can be suppressed to the minimum, which isuseful for the portable computer whose battery capacity is limited.

FIG. 29B is a perspective view illustrating an example of a cellularphone that the user can wear on the wrist like a wristwatch.

This cellular phone includes the following: a main body which includes acommunication device including at least a telephone function, andbattery; a band portion 9204 by which the main body is worn on thewrist; an adjusting portion 9205 for adjusting the band portion fixed onthe wrist; a display portion 9201; a speaker 9207; and a microphone9208.

The main body includes operating switches 9203. The operating switches9203 serve, for example, as a switch for turning on a power source, aswitch for changing display, a switch for instructing to start takingimages, or as a button for starting a program for the Internet when theswitch is pushed, which enables different functions to interact.

Data Input to this cellular phone is operated by touching the displayportion 9201 with a finger or an input pen, operating the operatingswitches 9203, or inputting voice into the microphone 9208. Note thatdisplayed buttons 9202 which are displayed on the display portion 9201are illustrated in FIG. 29B. Data Input can be performed by touching thedisplayed buttons 9202 with a finger or the like.

Further, the main body includes a camera portion 9206 including an imagepick-up means for converting an image of an object, which is formedthrough a camera lens, to an electronic image signal. Note that thecamera portion is not necessarily provided.

The cellular phone illustrated in FIG. 29B is provided with a receiverof a television broadcast and the like, and can display an image on thedisplay portion 9201 by receiving a television broadcast. In addition,the cellular phone illustrated in FIG. 29B is provided with a memorydevice and the like such as a memory, and can record a televisionbroadcast in the memory. The cellular phone illustrated in FIG. 29B mayhave a function of detecting location information such as GPS.

An image display device of a liquid crystal display panel, alight-emitting display panel such as an organic light-emitting elementor an inorganic light-emitting element, or the like is used as thedisplay portion 9201. The cellular phone illustrated in FIG. 29B iscompact and lightweight and the battery capacity of the cellular phoneillustrated in FIG. 29B is limited. Therefore, it is preferable that apanel which can be driven with low power consumption be used as adisplay device for the display portion 9201.

Note that FIG. 29B illustrates the electronic apparatus which is worn onthe wrist; however, this embodiment is not limited thereto as long as aportable shape is employed.

Example 1

The interaction between an oxide semiconductor layer and an oxygenmolecule was calculated using first-principle MD (molecular dynamics)simulation. In this example, CASTEP produced by Accelrys, Inc. was usedas the calculation software. The calculation conditions were set asfollows: the NVT ensemble was used, the period of time was 0.5picoseconds, and the temperature was 350° C. As the calculation method,a density functional theory with the use of the pseudo-potentialplane-wave method was employed. In addition, GGA-PBE was used for afunctional.

In this example, an amorphous structure formed of 12 indium atoms, 12gallium atoms, 12 zinc atoms, and 46 oxygen atoms was used as acalculation model of an IGZO surface. The primitive lattice used for thecalculation was a rectangular solid with dimensions of 1.02 nm×1.02nm×2.06 nm A Periodic boundary condition was used for the boundary. Theabove-described surface model to which an oxygen molecule is added wasused below.

FIG. 30A shows an initial state of the surface of the oxidesemiconductor layer and the oxygen molecule disposed in the vicinity ofthe surface of the oxide semiconductor layer. FIG. 30B shows locationsthereof after 0.5 picoseconds. In FIG. 30B, the oxygen molecule isadsorbed by the metal of the surface of the oxide semiconductor layer.The covalent bond of the oxygen molecule did not break within 0.5picoseconds.

However, an oxygen atom is more thermodynamically stable in the state ofbeing adjacent to a metal atom rather than in the state of being bondedto an oxygen atom. Further, as is seen from the structure model madeusing the measured density value of the oxide semiconductor layer, thespace inside the oxide semiconductor layer is too narrow for the oxygenmolecule to diffuse into while keeping the covalent bond. Thus, oxygenatoms are diffused into the oxide semiconductor layer when they come tothe thermodynamical equilibrium.

Next, a diffusion phenomenon of oxygen in an oxide semiconductor layerincluding a region with a high oxygen density and a region with a lowoxygen density, which is caused by heat treatment, was calculated. Theresults are described with reference to FIG. 31 and FIG. 32. In thisexample, Materials Explorer 5.0 manufactured by Fujitsu Limited was usedas the calculation software.

FIG. 31 shows a model of an oxide semiconductor layer that was used forthe calculation. In this example, an oxide semiconductor layer 701 had astructure in which a layer with a low oxygen density 703 and a layerwith a high oxygen density 705 are stacked.

For the layer with a low oxygen density 703, an amorphous structureformed of 15 indium atoms, 15 gallium atoms, 15 zinc atoms, and 54oxygen atoms was employed.

For the layer with a high oxygen density 705, an amorphous structureformed of 15 indium atoms, 15 gallium atoms, 15 zinc atoms, and 66oxygen atoms was employed.

Further, the density of the oxide semiconductor layer 701 was set at 5.9g/cm³.

Next, classical MD (molecular dynamics) simulation was performed on theoxide semiconductor layer 701 under conditions of the NVT ensemble and atemperature of 250° C. The time interval was set at 0.2 femtoseconds,and the total calculation period of time was 200 picoseconds. For themetal-oxygen bonding and the oxygen-oxygen bonding, a Born-Mayer-Hugginspotential was used. In addition, motion of atoms at the upper and lowerends of the oxide semiconductor layer 701 was fixed.

Next, the simulation results are shown in FIG. 32. A region from 0 nm to1.15 nm along the z axis indicates the layer with a low oxygen density703, and a region from 1.15 nm to 2.3 nm along the z axis indicates thelayer with a high oxygen density 705. The oxygen density distributionbefore the MD simulation is indicated by a solid line 707, and theoxygen density distribution after the MD simulation is indicated by abroken line 709.

As for the solid line 707, the oxygen density in the layer with a highoxygen density 705 is higher than that at the interface between thelayer with a low oxygen density 703 and the layer with a high oxygendensity 705. On the other hand, as for the broken line 709, the oxygendensity in the layer with a low oxygen density 703 and the oxygendensity in the layer with a high oxygen density 705 are even.

From the above, it can be found that in the case where the oxygendensity distribution is uneven like the stacked structure of the layerwith a low oxygen density 703 and the layer with a high oxygen density705, heat treatment makes oxygen diffuse from the higher density regionto the lower density region, so that the oxygen density becomes even.

The oxygen diffusion at that time is illustrated schematically in FIGS.33A to 33C. Oxygen 713 moves to a surface of an oxide semiconductorlayer 711 (see FIG. 33A). In the mode shown in FIG. 33A, metal (Me) isbonded to oxygen (O) in the oxide semiconductor layer 711. Next, theoxygen 713 is adsorbed on the surface of the oxide semiconductor layer711. FIG. 33B illustrates an oxide semiconductor layer 715 in whichoxygen is adsorbed to metal (Me) of the oxide semiconductor. After that,it is found that the adsorbed oxygen makes ion bonding with a metal ion(Me) contained in the oxide semiconductor layer and diffuses to theinside of the oxide semiconductor layer in the form of an oxygen atom(see FIG. 33C).

That is, the structure in which the oxide insulating layer 407 is formedon the oxide semiconductor layer 403 as described in Embodiment 1 makesthe oxygen density increase at the interface between the oxidesemiconductor layer 403 and the oxide insulating layer 407, so thatoxygen is diffused toward the lower oxygen density in the oxidesemiconductor layer 403; accordingly, the resistance of the oxidesemiconductor layer 403 is increased. In this manner, reliability of athin film transistor can be improved.

This application is based on Japanese Patent Application serial no.2009-164134 filed with Japan Patent Office on Jul. 10, 2009, the entirecontents of which are hereby incorporated by reference.

1. A method for manufacturing a semiconductor device, comprising:forming a gate electrode layer over a substrate having an insulatingsurface; forming a gate insulating layer over the gate electrode layer;forming an oxide semiconductor layer over the gate insulating layer;heating the oxide semiconductor layer in an oxygen atmosphere; forming asource and drain electrode layers over the oxide semiconductor layer;forming an oxide insulating layer which is in contact with part of theoxide semiconductor layer, over the gate insulating layer, the oxidesemiconductor layer, and the source and drain electrode layers; andperforming a heat treatment in an oxygen atmosphere or an inert gasatmosphere.
 2. A method for manufacturing a semiconductor device,comprising: forming a gate electrode layer over a substrate having aninsulating surface; forming a gate insulating layer over the gateelectrode layer; forming an oxide semiconductor layer over the gateinsulating layer; heating the oxide semiconductor layer in an oxygenatmosphere, so that the oxide semiconductor layer is dehydrated ordehydrogenated; forming a source and drain electrode layers over theoxide semiconductor layer; forming an oxide insulating layer which is incontact with part of the oxide semiconductor layer, over the gateinsulating layer, the oxide semiconductor layer, and the source anddrain electrode layers; and performing a heat treatment in an oxygenatmosphere or an inert gas atmosphere.
 3. A method for manufacturing asemiconductor device, comprising: forming an oxide semiconductor layerover an insulating layer; heating the oxide semiconductor layer in anoxygen atmosphere; forming a source and drain electrode layers over theoxide semiconductor layer; forming an oxide insulating layer which is incontact with part of the oxide semiconductor layer, over the insulatinglayer, the oxide semiconductor layer, and the source and drain electrodelayers; and performing a heat treatment in an oxygen atmosphere or aninert gas atmosphere.
 4. A method for manufacturing a semiconductordevice, comprising: forming an oxide semiconductor layer over aninsulating layer; heating the oxide semiconductor layer in an oxygenatmosphere, so that the oxide semiconductor layer is dehydrated ordehydrogenated; forming a source and drain electrode layers over theoxide semiconductor layer; forming an oxide insulating layer which is incontact with part of the oxide semiconductor layer, over the insulatinglayer, the oxide semiconductor layer, and the source and drain electrodelayers; and performing a heat treatment in an oxygen atmosphere or aninert gas atmosphere.
 5. The method for manufacturing a semiconductordevice according to any one of claims 1 to 4, wherein a temperature atwhich the oxide semiconductor layer is heated in the oxygen atmosphereis higher than or equal to 200° C. and lower than a strain point of thesubstrate.
 6. The method for manufacturing a semiconductor deviceaccording to any one of claims 1 to 4, wherein after the oxidesemiconductor layer is heated in the oxygen atmosphere, the oxidesemiconductor layer is held in the oxygen atmosphere.
 7. The method formanufacturing a semiconductor device according to any one of claims 1 to4, wherein after the oxide semiconductor layer is heated in the oxygenatmosphere, the oxide semiconductor layer is held in an inert gasatmosphere.